LINE BALANCING

Definisi
Line balancing merupakan suatu metode penugasan sejumlah pekerjaan yang saling berkaitan dalam satu lini produksi sehingga setiap stasiun kerja memiliki waktu yang tidak melebihi waktu siklus dari stasiun kerja tersebut. Line balancing berusaha menyeimbangkan seluruh lintasan yang ada dalam lini perakitan sehingga aliran produksi berjalan lancar.

Standard Minutes Operator to Perform Operation 1 2 3 4 5 0.49 0.31 0.25 0.44 0.54
Operator 3

How to Calculate Line Efficiency ?

Operator 4

Operator 5

Operator 2

Operator 1

Standard Minutes Allowed Wait Time Based on Operator to Perform Standard Slowest Operator Operation Minutes 1 2 3 4 5 0.49 0.31 0.25 0.44 0.54 2.03
5

0.05 0.23 0.29 0.1 0

0.54 0.54 0.54 0.54 0.54 2.7

S .M . A.M
1 1 5

X 100

Line Efficiency ?

Standard Minutes Allowed Wait Time Based on Operator to Perform Standard Slowest Operator Operation Minutes 1 2 3 4 5 0.49 0.31 0.25 0.44 0.54 2.03 Efficiency 0.05 0.23 0.29 0.1 0 0.54 0.54 0.54 0.54 0.54 2.7

0.44
75.19%

Opportunities for Improvements ?

0.54 0.25

0.31 0.49

Assembly Line (7 operations)

Operation Standard Minutes 1 1.5 2 2.25 3 1.25 4 2.5 5 3 6 2.75 7 1.75

Desired Rate of Production = 1000/day

Efficiency = 95%

1 day = 10 hours = 600 minutes

Thus R = 1000/600 = 1.67 units/minute

Numbers of Operator Needed in Assembly Line?

SM N R AM R
Operation 1 2 3 4 5 6 7 minutes/unit SM R E Standard Minutes 1.5 2.25 1.25 2.5 3 2.75 1.75 0.6 15 1.67 0.95 26.36842105

27 operators

Operation 1 2 3 4 5 6 7 minutes/unit

(standard Standard Minutes minutes)/(minutes/u Operators nit) 1.5 2.5 3 2.25 3.75 4 1.25 2.083333333 2 2.5 4.166666667 5 3 5 5 2.75 4.583333333 5 1.75 2.916666667 3 0.6 27

Output?

Slowest One?
Operation 1 2 3 4 5 6 7 (standard Standard Minutes minutes)/(minutes/u Operators nit) 1.5 2.5 3 2.25 3.75 4 1.25 2.083333333 2 2.5 4.166666667 5 3 5 5 2.75 4.583333333 5 1.75 2.916666667 3

0.5 0.5625 0.625 0.5 0.6 0.55 0.583333333

5 60 output 100 / hour 1000 / day 3

Line Balancing Problem

3.4 mins B 2.2 mins A
C 4.1mins E 2.7 mins

D
1.7mins

F
3.3 mins

G
2.6 mins

Question
1. What process is the bottleneck? 2. How much is the maximum production per hour? 3. How much the efficiency? 4. How to minimize work stations? 5. How should they be grouped? 6. New efficiency?

A. 73.2% B. 56.7% C. 69.7% D. 79.6% E. 81.2%

2.2 mins A

Calculate efficiency
3.4 mins B
E

C
4.1mins D 1.7mins F

2.7 mins

G 2.6 mins

3.3 mins

(2.2+3.4+4.1+2.7+1.7+3.3+2.6) 4.1x7
20 28.7

69.7%
1-69.7%=30.3% Balance Delay

Number of Workstation

task times N cycle time (bottleneck)

20 = 4.88 work stations 4.1

4 Stations
(5.6)
Station 1 2.2 A C 4.1 Station 2 (5.8) All under 6 minutes? D 1.7

20/24=83.3%

Line Balancing Solution

3.4 B Max prod./hour 60/6 Station 3 10 units/hour E

2.7

(6.0) Station 4

F 3.3

G 2.6

5 Stations

Line Balancing Problem

5.6 3.4 mins 20/5.6x5 = 20/28 = 71.4% B 2.2 mins A E

C
4.1mins

2.7 mins

Max Prod./hour 60/5.6 10.7 units/hour

D 1.7mins 5.0

F 3.3 mins

G 2.6 mins

40 secs

What is the minimum # of work stations? Round down. 59 secs

84 secs 3 2 4 5 6

34 secs

56 secs

45 secs

task times N
cycle time
40+59+84+56+34+45 = 318 318/84 = 3.78 or 3 work stations What is the efficiency with 6 operators?
Efficency %

number of stations cycle time

task times

100

318/6 x 84= 318/504 = 63%

99 secs 40 secs 59 secs 84 secs

3 Stations ?

118 secs
34 secs

318/3x118

56 secs

45 secs 101 secs

318/354 = 89.8%

Efficency %

number of stations cycle time

task times

100

99 secs 40 secs 59 secs 84 secs 84 secs

4 Stations?

79 secs
34 secs

318/4 x 99 = 318/396 = 80.3%

56 secs

45 secs

56 secs