assembly line balancing jaime joo mba 530 – section 1 brigham young university
TRANSCRIPT
Assembly Line Balancing
Jaime Joo
MBA 530 – Section 1
Brigham Young University
Outline• 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:
•Precedence relationship is complied with
•No workstation takes more than the cycle time to complete
•Operational 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
Work Station 1
Work Station 4
Work Station 3
Work Station 2
!? Zzz Zzz
10 sec 40 sec! 20 sec 15 sec
Overproduction!
Generates waste
Undesirable waiting
Balanced Line
Work Station 1
Work Station 4
Work Station 3
Work Station 2
25 sec 25 sec 20 sec 15 sec
•Promotes one piece flow
•Avoids overburden
•Minimizes wastes
•Reduces variation
Line Balancing prerequisitesPrior to balancing a line we must:
• Determine the required workstation cycle time (or TAKT time), matching the pace of the manufacturing process to customer demand
• Standardize the process
Classic approach to ALB
Also known as SALBP* (Simple Assembly Line Balancing Problem), the classic approach to ALB is an heuristic process to optimize assembly lines simplifying the problem to a basic level of complexity
*Dubbed SALBP by Becker and Scholl (2004)
Example The next table shows the tasks performed in a
production line. Our goal is to combine them into workstations. The assembly line operates 8 hours per day and the expected customer demand is 1000 units per day. Balance the line and calculate the efficiency and theoretical minimum number of workstations.
Example (cont.)Task Task Time
(sec)Preceding Task
A 13 -
B 11 A
C 15 A
D 20 B
E 12 B
F 13 C
G 13 C
H 18 D, E
I 17 F, G
J 15 H, I
K 9 J
Total Time: 156
Example (cont.)• Step 1: Draw a precedence diagram according to the given sequential relationship
K
9 sec
J
15 sec
I
17 sec
H
18 sec
G
13 sec
F
13 sec
E
12 sec
D
20 sec
C
15 sec
B
11 sec
A
13 sec
Example (cont.)• Step 2: Determine Takt time or Workstation Cycle Time
C=Production time per day / Customer demand (or output per day)
C= 28800 sec (8 hours) / 1000 units = 28.8
• Step 3: Determine the theoretical number of workstations required
N= Total Task Time / Takt time
N= 156 / 28.8 = 5.42 (~6 workstations)
Example (cont.)• Step 4: Define your assignment rules. For
this example our primary rule will be “number of following tasks” and the secondary rule will be “longest operation time”
Example (cont.)• Step 5: Assign tasks to workstations following the assignment rules
and meeting precedence and cycle time requirements
To form Workstation 1:
A
13 sec B
C
Following tasks: 5
Following tasks: 5
11 sec
15 secLot: 15>11!
WS1: A+C=28 sec
Cycle Time met!
Example (cont.)• Forming Workstation 2:
A
13 sec B
C
11 sec
15 sec
G
13 sec
F
13 sec
E
12 sec
D
20 sec
B+D>Cycle time!
LOT:_F&G>E
Arbitrarily choose F
WS2: Operation time=24 sec (<C)
Example (cont.)• Following the same criteria we achieve our balancing with
7 workstations
Workstation Task Task TimeRemaining Unassigned Time
Feasible Remaining Tasks
Task withmost followers
Task withLOT
A 13 15.8 B, C B, C CC 15 0.8 -B 11 17.8 E, F, G E, F, G F, GF 13 4.8 -
3 D 20 8.8 -G 13 15.8 E E 12 3.8 -
5 H 18 10.8 -6 I 17 11.8 -
J 15 13.8 KK 9 4.8 -
1
2
4
7
Example (cont.)• Step 6: Calculate Efficiency
– Efficiency= Total Task Time / (Actual number of workstations * Takt Time)
– Efficiency= 156 / (7*28.8) = 77%
How to interpret this efficiency?
Is this the best efficiency achievable?
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 I. 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.)Task Task Time
(sec)Preceding Task
A 13 -
B 11 A
C 15 A
D 20 B
E 12 B
F 13 5 C
G 13 8 C
H 18 D, E
I 17 F, G
J (new I) 15 H, F, G
K (new J) 9 I
Total Time: 156 126
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
J*
9 sec
I*
15 sec
H
18 sec
G
8 sec
F
5 sec
E
12 sec
D
C
15 sec
B
11 sec
A
13 sec
20 sec
*Previously J & K respectively
Let’s practice (solution)• Takt time
C = 28,800 sec / 1000 units = 28.8
• Theoretical number of workstations
N = 126/28.8 = 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:
Workstation Task Task TimeRemaining Unassigned Time
Feasible Remaining Tasks
Task withmost followers
Task withLOT
A 13 15.8 B, C BB 11 4.8 -C 15 13.8 E, F, G EE 12 1.8 -
3 D 20 8.8 -4 H 18 10.8
G 8 20.8 FF 5 15.8 II 15 0.8 -
6 J 9 19.8 -
1
2
5
Let’s practice (solution)• Efficiency = 126/(6*28.8) = 73%
Challenge: Is this the best efficiency achievable? Try to solve with LOT as the primary rule and you will obtain a 5 workstations balance, increasing efficiency to 87%
ALB in the real worldThe simple ALB problem approach is limited by some
constraints:
• Balance on existing and operating lines– Workstations have spatial constraints
– Some workstations cannot be eliminated
– Need to smooth workload among workstations
• Multiple operators per workstation– Different paces among operators, different lead times within the
same workstation
ALB in the real world (cont.)• Operator spatial constraints
– Different workstation imposed working positions– More than one task to be performed in what should be the space for
one task
• Multiple Products– Coping with different products, some operations are needed for
some products but not for others– Some products can introduce “peak times” in some workstations
• Different task times performed in different shifts– Particularly when introducing new employees or workers with some
degree of incapacity
Conclusion• Simply Assembly Line Balancing is a valid
method to optimize assembly lines. However, many variables found in real operating lines increase the complexity of the problem. More complex algorithms have been developed to solve the difficult task of balancing large scale industrial lines. Some of them are commercially available in software.
References• F. Robert Jacobs & Richard B. Chase “Operations and
Supply Management, The Core” McGraw-Hill/Irwin First Edition
• Emanuel Falkenauer “Line Balancing in the real world” Optimal Design
• Paul Swift. http://www.beyondlean.com/line-balancing.html