Work Analysis and Design Line Balancing

Ay e AKBALIK-RAPINE s

January 2011

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Problem solving steps

Select project (Pareto, Fish diagram, Gantt, PERT, Job/Worksite analysis guide) Get and present data (charts, computations) Analyze data (operation analysis) Develop ideal method (motion, work, equipment design) Present and install method (decision making tools) Develop job analysis Establish time standards (time study) Follow up

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Line Balancing -ideal case-

See Beyond Lean page Everyone is doing the same amount of work Variation is smoothed No one overburdened No one waiting Everyone working together in a balanced fashion

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Line Balancing

Example 1 Operation 1 = 5 min Operation 2 = 15 min Operation 3 = 10 min Questions What is the cycle time of this system? If each operation was 15 min, what happens? If we consider Operation 2 = 10 min ?

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Line Balancing

Example 1 What is the system efciency? What is the idle time percentage?

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Line Balancing

Example 1 What is the system efciency? efciency % = ( total actual standard minutes )% total allowed standard minutes

lead time efciency % = ( number of machines )% bottleneck time

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Line Balancing

Example 2 We want 960 pieces a day (with 8h a day) See the standard minutes for each operation below Operation Op 1 Op 2 Op 3 Standard minutes 1.2 min 2.4 min 1.9 min Number of operators ? ? ?

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Line Balancing

Operation Op 1 Op 2 Op 3

Standard minutes 1.2 min 2.4 min 1.9 min

Number of operators 3 5 4

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How to increase the efciency of the operation 2?

Reassign some of the work of operation 2 to the other operations Improve the method at operation 2 to decrease the cycle time Utilize a part-time worker

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Line Balancing, Example 3

Operation Op 1 Op 2 Op 3 Op 4 Op 5 Op 6 Op 7 Op 8

Standard minutes 1.25 min 1.38 min 2.58 min 3.84 min 1.27 min 1.29 min 2.48 min 1.28 min

Number of operators

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Line Balancing

Example 3 nd the number of operators to assign to each operation for a production of 700 pieces per day minimization of the storage costs are of high importance! no stock level is required at the end of day which operation determines the output from the line? nd the total number of pieces produced at the end of the day

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Assembly line improvement

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Disadvantages of element sharing

sharable parts, tasks Increase in material handling (parts are delivered to more than one location) Duplication of tooling, additional costs If any competence or experience is required from the operators, training periods... divisible tasks not very economical two times setup time, setup cost decrease on the efciency

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Assembly line balancing -a precedence chart-

Operation times are given as follows: 0.46, 0.35, 0.25, 0.22, 1.10, 0.87, 0.28, 0.72, 1.32, 0.49, 0.55.

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Kilbridge and Websters Heuristic

Rank operations according to their number of predecessors Assign rst operations with least number of predecessors In case of tie, choose operation with longest operation time Total time at each work station cannot exceed the total cycle time Precedence relationships must be satised

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Helgeson and Birnie (1961) method

Compute "Positional weight = Operation time + Total time of all operations that must follow it" Begin by assigning the operation with highest positional weight If there is a tie, break it by
higher operation time lower operation number

Total time at a station cannot exceed the total cycle time Precedence relationship must be satised

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Assembly line balancing -a precedence chart-

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Assembly line balancing -precedence matrix-

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Assembly line balancing -positional weights-

The system cycle time = 1.5 min is given.

End 202 - Work analysis and design Line Balancing

Assembly line balancing -balanced assembly line-

End 202 - Work analysis and design

Line Balancing