IE271_Lecture10 - IE271 Operations Analysis and Design...

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IE271 Operations Analysis and Design Lecture Notes 10 Assembly Line Balancing
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Line Balancing One particular design for manufacturing systems is to create serial workstations … and parts move through them sequentially, observing one or more operations in each workstation. (Product Layout) Station 1 Station 2 Station 3 Finished Goods
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Line Balancing The individual tasks required to complete the product are divided and assigned to workstations … … so that each work station performs the same operation on every unit of the product.
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Line Balancing Line balancing seeks to reduce the waiting time caused by unbalanced production times between individual work centers … … and ensures production is the same at all processes, both in quantities and timing
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Line Balancing Variances in the operators’ skills and capabilities are minimized … … by generating in advance well thought out and documented standard operations … and by ensuring that all operators are trained in these preferred operation methods
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Plant Rate and Takt Time Plant Rate / Takt Time: Maximum amount of time that must be spent to produce one item in order to meet the customer demand 480 minutes of working day Assume 15% allowance (for personal needs) 480 – 480 *0.15 = 408 minutes of working time Assume 90% efficiency 408 * 0.9 = 367 minutes effective working time per day Assume daily demand is 100 units 367 / 100 = 3.67 minutes per piece = R value
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Elemental Time Standard times for each of the work element in the whole process must be computed (with an appropriate method) The production line must be designed so that the plant rate is met
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Line Balancing Assembly Line Balancing 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 If the time required in each station is identical then the line is said to be perfectly balanced and no delays occur at the workstations
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Precedence Requirements
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