8/10/2019 04 Sisprod - Line Balancing
1/53
KESEIMBANGANESEIMBANGAN LINTASANINTASAN
Presentasi KuliahTKI-313 Sistem Produksi
Jurusan Teknik Universitas Muhammadiyah Surakarta
Dosen : Much Djunaidi
8/10/2019 04 Sisprod - Line Balancing
2/53
8/10/2019 04 Sisprod - Line Balancing
3/53
Manual Assembly Lines
Work systems consisting of multiple workers organized toproduce a single product or a limited range of products
Assembly workers perform tasks at workstations locatedalong the line-of-flow of the product Usually a powered conveyor is used
Some of the workstations may be equipped with portable
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
.
Factors favoring the use of assembly lines: High or medium demand for product
Products are similar or identical Total work content can be divided into work elements
To automate assembly tasks is impossible
8/10/2019 04 Sisprod - Line Balancing
4/53
Why Assembly Lines are Productive
Specialization of labor
When a large job is divided into small tasks and eachtask is assigned to one worker, the worker becomeshighly proficient at performing the single task
(Learning curve)
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Interchangeable parts
Each component is manufactured to sufficiently close
tolerances that any part of a certain type can beselected at random for assembly with its matingcomponent.
Thanks to interchangeable parts, assemblies do notneed fitting of mating components
8/10/2019 04 Sisprod - Line Balancing
5/53
Some Definitions
Work flow
Each work unit should move steadily along the line
Line pacing
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Workers must complete their tasks within a certaincycle time, which will be the pace of the whole line
8/10/2019 04 Sisprod - Line Balancing
6/53
Manual Assembly Line
A production line that consists of a sequence ofworkstations where assembly tasks areperformed by human workers
Products are assembled as they move along
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
At each station a portion of the total work content isperformed on each unit
Base parts are launched onto the beginning ofthe line at regular intervals (cycle time) Workers add components to progressively build the
product
8/10/2019 04 Sisprod - Line Balancing
7/53
Manual Assembly Line
Configuration of an n-workstation manual assembly line
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
The production rate of an assembly line is determined by
its slowest station.
Assembly workstation: A designated location along the
work flow path at which one or more work elements are
performed by one or more workers
8/10/2019 04 Sisprod - Line Balancing
8/53
Two assembly
operators working
on an engine
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
assembly line
(photo courtesy of
Ford Motor
Company)
8/10/2019 04 Sisprod - Line Balancing
9/53
Manning level
There may be more than one worker per
station.
Utility workers: are not assigned to
s ecific workstations.
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
They are responsible for
(1) helping workers who fall behind,
(2) relieving for workers for personal breaks,
(3) maintenance and repair
8/10/2019 04 Sisprod - Line Balancing
10/53
Manning level
Average manning level:
where
n
ww
M
n
i
iu
1
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
M=average manning level of the line,
wu=number of utility workers assigned to the system,
n=number of workstations,
wi=number of workers assigned specifically to stationifori=1,,n
8/10/2019 04 Sisprod - Line Balancing
11/53
Work Transport Systems-Manual Methods
Manual methods
Work units are moved between stations by theworkers (by hand) without powered conveyor
Problems:
Starving of stations
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
The assembly operator has completed the assignedtask on the current work unit, but the next unit has notyet arrived at the station
Blocking of stations
The operator has completed the assigned task on thecurrent work unit but cannot pass the unit to thedownstream station because that worker is not yetready to receive it.
8/10/2019 04 Sisprod - Line Balancing
12/53
Work Transport Systems-Manual Methods
To reduce starving,
use buffers
To prevent blocking,
provide space between upstream and downstream
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
stations.
But both solutions can result in higher WIP,
which is economically undesirable.
8/10/2019 04 Sisprod - Line Balancing
13/53
Work Transport Systems-Mechanized
Methods
Continuously moving conveyor: operates at constant velocity1. Work units are fixed to the conveyor
The product is large and heavy
Worker moves along with the product
2. Work units are removable from the conveyor Work units are small and light
Workers are more flexible compared to synchronous lines, less flexible than
asynchronous lines
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Synchronous transport (intermittent transport stop-and-goline): all work units are moved simultaneously between stations. Problem:
Task must be completed within a certain time limit. Otherwise the lineproduces incomplete units;
Excessive stress on the assembly worker. Not common for manual lines (variability), but often ideal for automated
production lines
Asynchronous transport : a work unit leaves a given station whenthe assigned task is completed. Work units move independently, rather than synchronously (most flexible one).
Variations in worker task times
Small queues in front of each station.
8/10/2019 04 Sisprod - Line Balancing
14/53
Coping with Product Variety
Single model assembly line (SMAL)
Every work unit is the same
Batch model assembly line (BMAL ) multiple modelline
Two or more different products
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Products are so different that they must be made inbatches with setup between batches
Mixed model assembly line (MMAL)
Two or more different models
Differences are slight so models can be madesimultaneously with no setup time (no need for batchproduction)
8/10/2019 04 Sisprod - Line Balancing
15/53
Coping with Product Variety
Advantages of mixed models over batch order models
No production time is lost during changeovers
High inventories due to batch ordering are avoided
Production rates of different models can be adjusted as
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
pro uc eman c anges.
Disadvantages of mixed models over batch order models
Each station is equipped to perform variety of tasks (costly)
Scheduling and logistic activities are more difficult in thistype of lines.
8/10/2019 04 Sisprod - Line Balancing
16/53
Analysis of Single Model Lines
The formulas and the algorithms in this section aredeveloped for single model lines, but they can beextended to batch and mixed models.
The assembly line must be designed to achieve aproduction rate sufficient to satisfy the demand.
Demand rate production rate cycle time
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Annual demand Da must be reduced to an hourlyproduction rate Rp
where
Da = annual demand
Rp = hourly production rate
Sw= number of shifts/week
Hsh = number of hours/shift
shw
ap
HS
DR
52
8/10/2019 04 Sisprod - Line Balancing
17/53
Determining Cycle Time
Now our aim is to convert production rate, Rp, to cycle time,Tc.
One should take into account that some production time willbe lost due to
equipment failures
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
,
material unavailability,
quality problems,
labor problems.
Line efficiency (uptime proportion): only a certain proportion
of the shift time will be available.
where production rate, Rp, is converted to a cycle time, Tc,
accounting for line efficiency, E.
pc
R
ET
60
8/10/2019 04 Sisprod - Line Balancing
18/53
Number of Stations Required
Work content time (Twc): The total time of all workelements that must be performed to produce one unitof the work unit.
The theoretical minimum number ofstations that willbe required to on the line to produce one unit of the
work unit, w*:
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
w* = Minimum Integer
where
Twc= work content time, min;
Tc= cycle time, min/station
If we assume one worker per station then this gives theminimum number ofworkers
c
wc
T
8/10/2019 04 Sisprod - Line Balancing
19/53
Theoretical Minimum Not Possible
Repositioning losses: Some time will be lost
at each station every cycle for repositioning the
worker or the work unit; thus, the workers will
not have the entire Tceach cycle
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Line balancing problem (imperfect
balancing): It is not possible to divide the work
content time evenly among workers, and some
workers will have an amount of work that isless than Tc
8/10/2019 04 Sisprod - Line Balancing
20/53
Repositioning Losses
Repositioning losses occur on a productionline because some time is required eachcycle to reposition the worker, the work unit,or both
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
,for the worker to walk from the unit justcompleted to the the upstream unit entering thestation
In conveyor systems, time is required toremove work units from the conveyor andposition it at the station for worker to performhis task.
8/10/2019 04 Sisprod - Line Balancing
21/53
Repositioning Losses
Repositioning time = time available eachcycle for the worker to position = Tr
Service time = time available each cycle for
the worker to work on the product = Ts
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Service time Ts = Max{Tsi} Tc Tr
where Tsi= service time for station i, i=1,2,..,n
Repositioning efficiency Er=c
rc
c
s
T
TT
T
T
8/10/2019 04 Sisprod - Line Balancing
22/53
Cycle Time on an Assembly Line
Components of cycle time at several stations ona manual assembly line
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Tsi=service time, Tr=repositioning time
8/10/2019 04 Sisprod - Line Balancing
23/53
Line Balancing Problem
Given:
The total work content consists of many distinct
work elements
The sequence in which the elements can be
erformed is restricted
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
The line must operate at a specified cycle time
(=service time + repositioning time)
The Problem:
To assign the individual work elements to
workstations so that all workers have an equal
amount of work to perform
8/10/2019 04 Sisprod - Line Balancing
24/53
Assumptions About Work Element Times
1. Element times are constant values
But in fact they are variable
2. Work element times are additive The time to perform two/more work
elements in sequence is the sum of the
individual element times
Additivity assumption can be violated (dueto motion economies)
8/10/2019 04 Sisprod - Line Balancing
25/53
Work Element Times
Total work content time Twc
Twc=
where Tek= work element time for element k
en
k
ekT1
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
the service time for that station
Tsi=
The station service times must add up to the total workcontent time
Twc=
ik
ekT
n
i
siT1
8/10/2019 04 Sisprod - Line Balancing
26/53
Constraints of Line Balancing Problem
Different work elements require different times.
When elements are grouped into logical tasks and
assigned to workers, the station service times, Tsi, are
likely not to be equal.
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Simply because of the variation among work element
times, some workers will be assigned more work.
Thus, variations among work elements make it difficult toobtain equal service times for all stations.
8/10/2019 04 Sisprod - Line Balancing
27/53
Precedence Constraints
Some elements must be done before the
others.
Restrictions on the order in which work
elements can be erformed
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Can be represented graphically (precedence
diagram)
8/10/2019 04 Sisprod - Line Balancing
28/53
Example:
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Grommet : sealant like ring
8/10/2019 04 Sisprod - Line Balancing
29/53
Example:
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Grommet : sealant like ring
8/10/2019 04 Sisprod - Line Balancing
30/53
Example: A problem for line balancing
Given: The previous precedence diagram and the
standard times. Annual demand=100,000 units/year. The
line will operate 50 wk/yr, 5 shifts/wk, 7.5 hr/shift. Uptime
efficiency=96%. Repositioning time lost=0.08 min.
Determine
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
(a) total work content time,
(b) required hourly production rate to achieve the annual
demand,
(c) cycle time,(d) theoretical minimum number of workers required on
the line,
(e) service time to which the line must be balanced.
8/10/2019 04 Sisprod - Line Balancing
31/53
Example: Solution
(a) The total work content time is the sum of the workelement times given in the table
Twc=4.0 min
(b) The hourly production rate
units/hr33.53)5.7)(5(50
000,100
pR
en
k
ekwc TT1
shw
a
p HS
DR
50
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
(c) The corresponding cycle time with an uptimeefficiency of 96%
(d) The minimum number of workers:
w* = (Minimum Integer 4.0 /1.08=3.7)=4 workers
(e) The available service time
Ts=1.08-0.08=1.00 min
min08.133.53
)96.0(60cT
p
cR
ET
60
c
wc
T
Tw *
rcs TTT
8/10/2019 04 Sisprod - Line Balancing
32/53
Measures of Balance Efficiency
It is almost imposible to obtain a perfect line balance
Line balance efficiency, Eb:
Eb = Perfect line: Eb = 1s
wc
wT
T
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Balance delay, d:
d= Perfect line: d= 0
Note that Eb + d = 1 (they are complement of each
other)
s
wcs
wT
TwT
8/10/2019 04 Sisprod - Line Balancing
33/53
Overall Efficiency
Factors that reduce the productivity of amanual line
Line efficiency (Availability), E,
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
, r,
Balance efficiency (balancing), Eb,
Overall Labor efficiency on the assembly line = br EEE
c
rc
c
s
r T
TT
T
T
E
s
wc
b wT
T
E pc R
E
T
60
8/10/2019 04 Sisprod - Line Balancing
34/53
Skip - Worker Requirements
Skip this part
The actual number of workers on the
assembly line is given by:
w= Min Int wcwcwcp TTTR
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
where
w=number of workers required
Rp=hourly production rate, units/hrTwc=work content time per product, min/unit
c
rc
c
sr
T
TT
T
TE
s
wcb
wT
TE
sbcbrbr TETEEEEE60
p
cR
ET
60
8/10/2019 04 Sisprod - Line Balancing
35/53
Continously moving conveyors
- Workstation considerations
Total length of the assembly line
where L=length of the assembly line, m: Lsi=length of station i, m
Constant speed conveyor: (if the base parts remain fixed during
n
iis
LL1
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
their assembly)
Feed rate
fp=1/Tc
where fp=feed rate on the line, products/min
Center-to-center spacing between base parts
sp=vc/fp=vcTc
where sp= center-to-center spacing between base parts, m/part and
vc=velocity of the conveyor, m/min
8/10/2019 04 Sisprod - Line Balancing
36/53
Continously moving conveyors
- Tolerance Time
Defined as the time a work unit spends inside theboundaries of the workstation
Provides a way to allow for product-to-product variations
in task times at a station
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Tt=
where
Tt= tolerance time, min;
Ls = station length, m (ft);
vc= conveyor speed, m/min (ft/min)
c
s
v
8/10/2019 04 Sisprod - Line Balancing
37/53
Continously moving conveyors
-Total Elapsed Time
The time a work unit spends on the assembly
line.
ET= tc
nT
v
L
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
where
ET= total elapsed time, min;
Tt= tolerance time, min;L = length of the assembly line, m (ft);
vc= conveyor speed, m/min (ft/min)
8/10/2019 04 Sisprod - Line Balancing
38/53
Line Balancing Objective
To distribute the total work content on the assembly lineas evenly as possible among the workers
Minimize (wTs Twc)
or
w
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Subject to:
(1)
(2) all precedence requirements are obeyed
s
ik
ek TT
i
sis
1
8/10/2019 04 Sisprod - Line Balancing
39/53
Line Balancing Algorithms Heuristics
1. Largest candidate rule
2. Kilbridge and Wester method
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
. ,
known as the Helgeson and Birne method
In the following descriptions, assume one
worker per workstation
8/10/2019 04 Sisprod - Line Balancing
40/53
Largest Candidate Rule
List all work elements in descending order based on theirTekvalues; then,
1. Start at the top of the list and selecting the first elementthat satisfies precedence requirements and does notcause the total sum of Tek to exceed the allowable Tsvalue
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
When an element is assigned, start back at the top of thelist and repeat selection process
2. When no more elements can be assigned to the current
station, proceed to next station
3. Repeat steps 1 and 2 until all elements have beenassigned to as many stations as needed
8/10/2019 04 Sisprod - Line Balancing
41/53
Solution for Largest Candidate Rule
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
8/10/2019 04 Sisprod - Line Balancing
42/53
Example:
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Grommet : sealant like ring
8/10/2019 04 Sisprod - Line Balancing
43/53
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
8/10/2019 04 Sisprod - Line Balancing
44/53
Solution for Largest Candidate Rule
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
8/10/2019 04 Sisprod - Line Balancing
45/53
Solution for Largest Candidate Rule
Physical layout of workstations and assignmentof elements to stations using the largest
candidate rule
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
8/10/2019 04 Sisprod - Line Balancing
46/53
Ranked Positional Weights Method
A ranked position weight (RPW) is calculated for eachwork element
RPW for element k is calculated by summing the Tevalues for all of the elements that follow element kin the
diagram plus T itself
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Work elements are then organized into a list according to
theirRPWvalues, starting with the element that has the
highest RPWvalue
Proceed with same steps 1, 2, and 3 as in the largest
candidate rule
8/10/2019 04 Sisprod - Line Balancing
47/53
Solution for Ranked Positional Weights
Method
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
8/10/2019 04 Sisprod - Line Balancing
48/53
Example:
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Grommet : sealant like ring
8/10/2019 04 Sisprod - Line Balancing
49/53
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
8/10/2019 04 Sisprod - Line Balancing
50/53
Other Considerations in Line Design
Methods analysis To analyze methods at bottleneck or other troublesome
workstations
improved motions,
better workplace layout,
special tools to facilitate manual work elements
product design
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Utility workers
To relieve congestion at stations that are temporarilyoverloaded
Preassembly of components
Prepare certain subassemblies off-line to reduce workcontent time on the final assembly line
8/10/2019 04 Sisprod - Line Balancing
51/53
Other Considerations - continued
Storage buffers between stations To permit continued operation of certain sections of
the line when other sections break down
To smooth production between stations with large
task time variations
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Parallel stations
To reduce time at bottleneck stations that have
unusually long task times
Worker (Labor) Shifting with crosstraining
Temporary (or periodic) relocation to expedite or to
reduce subassembly stocks
8/10/2019 04 Sisprod - Line Balancing
52/53
Most Follower Rule
1
4
38
9 10
8
5
3
5
Item iMost Follower
1 9
2 5
3 4
4 4
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
6
5
72 4
9
4
6 10
6
19191919
5 4
6 4
7 3
8 3
9 2
10 1
19/19 16/19 15/19 10/19
8/10/2019 04 Sisprod - Line Balancing
53/53
We omit
Worker Requirements in 4.2.2
4.3.2 Kilbridge and Western Method
Work Systems and the Methods, Measurement, and Management of Work
by Mikell P. Groover, ISBN 0-13-140650-7.
2007 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
.
Top Related