Line balancing is the problem of assigning operation to workstation along an assembly line, in such a way that assignment is optimal in some sense. Decisions associated with line balancing have a direct influence on the costs of production. Suppose there are three machines work stations a, b and c, which can process 5, 10 and 15 pieces per unit time respectively and the pieces flow from a to b to c precedence constraint. Learn vocabulary, terms, and more with flashcards, games, and other study tools. A few comments on parallel processes for balancing.
An example of line balancing assigning tasks to stations a precedence diagram is a lot like a process flow diagram. Assembly line balancing alb is the problem of assigning tasks to successive workstations by satisfying some constraints and optimizing a performance measure. Darelan assembly chart oriented assembly line balancing approach international journal of production research, 6 1990, pp. View test prep lecture3assemblylinebalancingextranotesrevised from electrical 102 at georgia institute of technology. Importance, productivity ratio, productivity measurement.
The course lean manufacturing line balancing and facilities location is the third course in the applied operations management series. Smart material, adaptive structures and intelligent mechanical systems iitk. Assigning numbers of operators or machines to each operation of an assembly line so as to meet the required production rate with a minimum of idle time explanation of assemblyline balancing. Labour flexibility is the key to effective resource management. Assembly line balancing problem assembly line balancing is the problem of assigning various tasks to workstations, while optimizing one or more objectives without violating any restrictions imposed on the line. In production line workstations and work centers are arranged in a sequence of task to be done along a straight or curved line. The goal is to achieve the desired output rate with the smallest number of workstations.
Lectures notes on production and operation management vssut. Apart from the task mentioned above, this group includes a number of key computational problems. Lean line balancing for an electronics assembly line. Many forms of wastes such as inventory, waiting time, and transport are eliminated.
Waste identification and elimination value stream analysis, setup reduction, part. For example, the target is not fixed, but can be overshot slightly if necessary. Balance the line by assigning specific tasks to workstations. Line balancing, aggregate planning, chase planning, expediting, controlling aspects. Lectures notes on production and operation management.
Lecture 21 sequencing and line balancing lecture 22 flow control lecture 23 dispatching, centralized and decentralized dispatching. Many tasks must be performed, and the sequence is flexible. Productionline balancing study tends to employ thought and ingenuity to change conditions. Srinivasan, department of management studies, iit madras. Lecture 33 product layouts and assembly line balancing. The idea of workers checking and doing minor repair work on their own equipment possibly decreases the risk of equipment. As yet, the computation involved for a practical problem would be quite large. Result showsthat there is significant improvement on assembly line when mathematical model reconstructed, as their cycle time ct is improved. Mixed assembly line balancing method in scenarios with. Assembly line balancing free download as powerpoint presentation. Line balancing this is an analysis process which tries to equally divide work to be carried out in a production process among workstations. And also how do balance it on computer, and why it is not really good. Arun kanda, department of mechanical engineering, iit delhi.
Therefore, a lean line balancing could support the wip smoothly flows through the line with minimal or no buffers between steps of assembly process 4. This project mainly focuses on improving overall efficiency of single model assembly line by reducing the bottleneck activities, cycle time and distribution of work load at each work station by line. Feasible solutions depend on work recently presented on integer solutions to linearprogramming problems. An alternative approach for design and planning conference paper pdf available august 2016 with 1,288 reads how we measure reads. Production lines, product design, market demand, number of workers, technology or machines. The processes used to accomplish the assembly of the components can be divided into three major categories. Line balancing is leveling the workload across all processes in a cell or value stream to remove bottlenecks and excess capacity. As small improvements in the performance of the system can lead to significant monetary consequences, it is of utmost importance to develop practical solution procedures that yield highquality design decisions with minimal computational requirements.
Match the production rate after all wastes have been. A mathematical programming model of the assembly line balancing problem dennis l. Introduction in the moderns era, process efficiency in manufacturing especially in automotive industry is very crucial in dealing with the demand of the customers. Application notes static and dynamic balancing of rigid. Introduction while looking at product layout there are many aspects to focus on. List the sequential relationships among tasks and then draw a precedence diagram. A study on line balancing in assembly line at automotive. Lecture 33 product layouts and assembly line balancing youtube. The concept of an assembly line al came to the fact when the finished product is inclined to the perception of product modularity. It is a particularly difficult, computably complex task, belonging to the npcomplete class. Minimization of the number of workstations and maximization of the production rate are the most common goals. Lecture series on project and production management by prof. This course introduces the process of line balancing in lean manufacturing, which involves assigning tasks to workstations, so that workstations have approximately equal time requirements.
Assembly line balancing alb and sequencing is an active area of optimization research in operations management. Assign tasks to first workstation, using rules and staying within cycle time. Assembly line balancing is a hard problem concerned with the assignment of individual work elements or tasks to workstations so as to minimize the assembly cost as much as possible. Arranging stations in a sequence line for the product to move from one station to the next until its completion at the end of the line.
Abstract assembly line balancing is to know how tasks are to be assigned to workstations, so that the predetermined goalis achieved. Lean line balancing has been done in many industries 4. Assembly systems and line balancing discrete products are assembled from components. Assembly line balancing home northeastern university. Closing a series of six posts this post includes a few tips and tricks when line balancing. Line balancing part 6 tips and tricks for balancing.
Aggregate production planning 2 lectures operational decisions over the short term 4 lectures 15. Layouts for advanced manufacturing systems production planning over medium term horizon 5 lectures. Productionline design and operation is more art than science. Assembly line balancing alb is one of the important problems of productionoperations management area. Nearly impossible to reach perfect balance things to consider sequence of tasks is. Calculate theoretical minimum number of workstations. Batch model lines produce small lots of different products on the line in batches. In this chapter, we introduce the fundamentals of lean manufacturing. Since introduction of assembly lines by henry ford, linebalancing has been an optimisation problem of important industrial importance.
Line balancing means balancing the line, for example balancing the production line or an assembly line. Assembly planners line balancing brings flexibility to line rebalancing. How can assemblyline balancing be used in organization. Assembly line balancing problem of sewing lines in garment. Line balancing vs line of balance line balancing line balancing is the technique of balancing the unbalanced production line so that the idle time of machines in the assembly line get reduced which in turn result in reduced overall cycle time in making of a product.
Repeat for following workstations until all tasks are assigned. Digital manufacturing simplifies complex assembly line balancing problems with faster. Simple assembly line balancing assembly line balancing is one of the challenges that appear when technological process of an assembly is being developed. Are used in highproduction situations where the work to. This performance measure is usually the minimization of the number of workstations utilized over the assembly line. Balancing and sequencing problem varies with the types of als. A mathematical programming model of the assembly line. Bottlenecks and points of congestions are eliminated by line balancing so that the raw.
Linearprogramming solutions to the assemblyline balancing problem are offered in two forms. Assembly line balancing introduction to industrial engineering the line balancing problem the problem is to arrange the individual processing and assembly tasks at the workstations so that the total time required at each workstation is approximately the same. Assembly line balancing is the problem of assigning operations to workstations along an assembly line, in such a way that the assignment be best in some sense. How to give everyone enough, but not too much work for the limited time. A constraint slows the process down and results if waiting for downstream operations and excess capacity results in waiting and no absorption of fixed costs.
Task and time details are maintained in the process library and used for line balance planning. Line balancing is the assignment of work elements to stations in a line. For instance, single model line produces a single product over the line. Line balancing techniques to improve productivity using. Assembly line balancing is a production strategy that sets an intended rate of production to produce a particular product within a particular time frame. Objective is to minimize the imbalance between machines or personnel while meeting required output. Lean manufacturing course line balancing and facilities. Assembly line balancing economies technology scribd.
Research in genetic algorithm ga and gga is then discussed. Facility layout, tool changes, workstation indexes remains fairly constant. Line balancing, line balancing operations management. Chapter 18 lean manufacturing pennsylvania state university.
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