Assembly Line Design

Gajanan Ganage : 104

Ashish Kadam : 106
Asad Patrick : 111
Manas Rane : 112

What is an assembly line?

Manufacturing process in which

parts are added as the semi-finished
assembly moves from workstation to
workstation where the parts are added
in sequence until the final assembly
is produced.
By mechanically moving the parts to
the assembly work and moving the
semi-finished assembly from work
station to work station, a finished
product can be assembled faster and
with less labor than by having
workers carry parts to a stationary
piece for assembly.

Why assembly line?

3

Market Demand/Month = 1000

2

Activities = 6
Available hrs = 200

Desired cycle time = 12 min

Cycle time = 16 min

Main Objective: To Reduce Cycle time

Types of assembly lines?

Mainly based on the production strategy and product variants
Single model:
No variants
Work at all stations remains same
Outcome product of the line is the same
Multi model:
Products that have different variants.
No resource constraints for assembling
May have different operation times for different variants.
Multi-model:
Product variants are produced in batches.
Require setup for change of tools or another equipment.

Objectives:
Minimize the work imbalance.
Minimize the number of workstations.
Minimize the idle time.

How to achieve?
Grouping of tasks into workstations.
The feasible range of cycle times.
Line balancing methods
Choice of the best design.

System diagram:
INPUTS

OUTPUTS

- Demand
- Task time
- Precedence among
tasks
- Efficiency factors

Assembly Line

- Task to station
assignments
- The number of
stations/workers

Influencing factors:
Mass Production

Mass Customization

Goal

Delivering Goods and services at prices

low enough that nearly everybody can
afford it.

Delivering Affordable Goods and

services with enough variety and
customization that nearly every one
finds what they want

Economics

Economics of Scale

Economics of Scope

Customer
Involvemen
t

Buy

Choose

Production
System

Dedicated Manufacturing System

Reconfigurable Manufacturing System

Product

Standardized Product built to

inventory/stock

Standardized modules assembled on

customer Needs

Influencing factors:
Key Features

Mass Production

Mass Customization

Stable Demand
Large Homogenous Markets
Low Cost
Consistent Quality
Standardized goods and services
Long Product Development Cycle
Long Product Life Cycle

Fragmented Demand
Heterogeneous Niches
Low Cost
High Quality
Customized Goods and services
Short Product Development Cycle
Short Product Life Cycle

Influencing factors:
Influencing Factorsics

Auto

Defence

Fast Food

Mass Production

Mass Customization

Data collection methods:

- Precedence diagram
- Market Demand Analysis

- Individual task time

Rank Positional weights Method

The positional weights on a work element is its own processing time plus the
processing times of all the following work elements

At each work station a list of eligible jobs is prepared for replacement

In RPW, the work element with the highest positional weight is selected and
assigned to the current work station

Mathematical Modeling:
3

5
1

No of work elements=12

12

Precedence Diagram

10

11

Tmax Cycle Time Ti

7 Cycle Time (5+3+4.7)
50
Let the Desired Cycle time be 10 units

Assigning Positional Weights

33

28

15

1
50

33

30

24

13

9
4

10

15

7
12

4
11

11
Duration

j
Element Number
i

Positional Weightage

Grouping Activities based on RPW

33

28

15

13

1
6

24

50

1,
4
8

2,
5

30

3,
6

12
4

11

10
33

15

11

10,7,
9

8,11
7

12
10

Pictorial View of Final Assembly line

Performance Measures
Line Efficiency:
= STi/(K*CT)*100%
= (50/6*10)*100= 83.3%
Balance Delay= (1 - LE)*100=16.6%
Smoothness Index= ( STmax- STi)
= (4+1+1+16+4)= 5.09
Output/day = 420 min/10 min = 42 units

If Cycle time = 8 , # Workstations = 8 but output = 52 & Efficiency = 78.12%

If Cycle time = 15, # Workstations = 4 but output = 28 & Efficiency = 83.33%

Conclusion

Increasing Cycle time, Decreases # Workstations but decreases output

Decreasing Cycle time, Increases # Workstations but Increases output

Pizza operations
D

Task

Description

A
B
C
D
E
F
G
H

Roll dough
Add pizza sauce
Sprinkle cheese
Add sausage
Add pepperoni
Add mushrooms
Shrinkwrap pizza
Add Label

25 sec

A
60 sec

B
30 sec

C
35 sec

E
35 sec

G
15 sec

F
22 sec

Runs 8 hours per day = 28800 seconds

Want to produce 300 pizzas per day

H
23 sec

Task
time
(sec)
60
30
35
25
35
22
15
23
245

Preceding
task

A
B
C
C
C
D,E,F
G

Pizza operations

Cycle time = 28800 sec per day/ 300 pizzas per day = 96 seconds

Theoretical minimum no of work stations

N= sum of task time/cycle time = 245 seconds/96 seconds per station
= 2.55 stations = 3 stations

Efficiency = sum of task times/(# workstations*Cycle time)

= 245 seconds/ (3stations* 96 seconds/statins) = 85.1%

Pizza operations
station
1

Eligible
task

Assigned
Task

Task
Time

A
B
C
D, E, F
D, F
F
G
H

A
B
C
E
D
F
G
H

60
30
35
35
25
22
15
23

Cumulative
Idle time
Time
60
90
35
70
95
22
37
60

36
6
61
26
1
74
59
36

Thank You