Major management concern balancing the line only

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Major management concern: balancing the line only. Advantages: simple and easy to planning, scheduling, and controlling 2. Mixed-model line: More than two products are processed on the same line. Items are different. Major management concerns: both items sequencing & line balancing are to be considered together to achieve better performance. Advantages: high utilization/ eliminate line changeovers/… Why mixed? Capacity of line > Demand of a single product
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Subjective Considerations in Assembly Line Balancing Problems Job enlargement vs. job specialization- employee motivation Choice of cycle time- speed of line vs. balance delay Space requirements Task decomposition – can a major task really be broken down? Special materials handling considerations Safety Quality control Flexibility of design
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Production lines: Western vs. Japanese Western Japanese Top priority: line balancing Top priority: flexibility Strategy: stability- long production runs so that nee to rebalance seldom occurs Strategy: flexibility- expect to rebalance often to match output to changing demand Assume fixed labor assignments Flexible labor: move to the problems or to where the current workload is Use inventory buffers to cushion effects of equipment failure Employ maximal preventive maintenance to keep equipment from breaking down Need sophisticated analysis (e.g. using computers) to evaluate and cull the many options Need human ingenuity to provide flexibility and ways around bottlenecks Planned by staff Supervisor may lead design effort and will adjust as needed
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Production lines: Western vs. Japanese Western Japanese Plan to run at fixed rate, send quality problems off line Slow for quality problems, speed up when quality is right Linear or L- shaped lines U- shaped or parallel lines Conveyorized material movement is desired Put stations close together and void conveyors Buy “ super machines ” and keep them busy Make (or buy) small machines, add more copies as needed Applied in labor- intensive final assembly Applied even to capital- intensive subassembly and fabrication work Run mixed models where labor content is similar from model to model Strive for mixed-model production, even in subassembly and fabrication
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