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Jaime Joo
MBA 530 ± Section 1
Brigham Young University
=utline
What is Assembly Line Balancing?
How can Assembly Line Balancing benefit
your operations?
Classic approach to ALB
Let¶s practice!
ALB in the real world
Conclusions
What is Assembly Line Balancing (ALB)?
ALB is the procedure to assign tasks to
workstations so that:
'
is complied with
No workstation takes more than the
to complete
=perational idle time is minimized
How can Assembly Line Balancing benefit
your operations?
A balanced line:
Promotes one piece flow
Avoids excessive work load in some stages
(overburden)
Minimizes wastes (over-processing, inventory,
waiting, rework, transportation, motion)
Reduces variation
Unbalanced Line
£ K
Undesirable waiting
=verproduction!
Generates waste
Balanced Line
£ £ £ £
xample (cont.)
Step Ñ: Determine Takt time or Workstation Cycle Time
C=Production time per day / Customer demand (or output per day)
C= Ñ8800 sec (8 hours) / 1000 units = Ñ8.8
To form Workstation 1:
11 sec
13 sec Following tasks: 5
Lot: 15>11!
15 sec
Following tasks: 5
WS1: A+C=Ñ8 sec
Cycle Time
met!
xample (cont.)
Forming Workstation Ñ:
Ñ0 sec
B+D>Cycle time!
11 sec
13 sec 1Ñ sec
L=T:_F&G>
15 sec 13 sec
13 sec
Arbitrarily choose F
xample (cont.)
Following the same criteria we achieve our balancing with
7 workstations
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xample (cont.)
Step 6: Calculate fficiency
Let¶s Practice
We have found a new market for our
product. This market is less demanding so
we have decided not to include a particular
feature, specifically the feature added by
task . As a consequence, task time in F
drops to 5 seconds and task time in G drops
to 8 seconds. Balance the line according to
the other conditions.
Let¶s practice (cont.)
D D D
D
A 13 -
B 11 A
C 15 A
D Ñ0 B
1Ñ B
F 13 5 C
G 13 8 C
H 18 D,
17 F, G
J (new ) 15 H, F, G
K (new J) 9
Total Time: 156 1Ñ6
Let¶s practice (cont.)
Let¶s take some time to solve this new
problem. This time we will calculate
keeping the primary and secondary rules as
in the original problem.
Let¶s practice (solution)
Precedence diagram
Ñ0 sec
11 sec 18 sec
1Ñ sec
13 sec
15 sec 9 sec
5 sec
15 sec
8 sec
*Previously J & K respectively
Let¶s practice (solution)
Takt time
C = Ñ8,800 sec / 1000 units = Ñ8.8
Theoretical number of workstations
N = 1Ñ6/Ñ8.8 = 4.38 (~5 workstations)
Primary rule: number of following tasks
Secondary rule: longest operation time
Let¶s practice (solution)
Following the rules and observing cycle time and precedence
we obtain:
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