Outline

Case study 4 BTP

Design of manufacturing systems Assembly line

Top managements questions

Solution: objective, procedure, results
Concluding remarks

BTP Case Study 1

BTP - top managements questions

As the assembly process is quite simple, it has been

decided to use a synchronous line (i.e. machine-
paced).
Assembly Line Balancing with zoning restriction

How many stations do we need to meet demand?

Which operations are assigned to each station?

BTP Case Study 2

BTP - draft solution
Objective

To balance the new line

by using the Maximum Operator Utilization Model

remember that utilization rate: working times assigned to a station / CT
maximum utilization rate: 95%

by keeping the probability of no-completion under the 7% in each station

BTP Case Study 3

 BTP - draft solution
Steps

1. Draw the precedence graph (assembly graph)

2. Calculate the total task time T (sum of all task times)
Defined as total assembly work content or, equivalently, total assembly time
3. Calculate the cycle time CT
CT = available time / demand
4. Calculate the minimum number of stations K*:
K* = T/(CT )
is the maximum level of acceptable utilization (O < 1)
actual solution might have K** > K* number of stations

BTP Case Study

4
BTP - draft solution
Steps
5. Assign tasks to stations, respecting the constraints (CT, precedence, ,
etc.)
If there is more than one task available to be assigned, use a rule to prioritise
tasks

Rules:
1. Prioritize tasks in order of longest task time (first rule)
2. Prioritize tasks in order of the largest number of following tasks (second
rule)

If there is any task that requires more than the defined CT use parallel
stations

At the end: calculation of the probability of no-completion

RTk = CT ti Zk =
RT k

BTP Case Study

iS

iS
i
2

5
BTP 1. Precedence Diagram
301

303 304 305 306 307 308 309

310

101 102 311 302

201 202 203 204 205 402

401 403 404

501 502 503 601 602 603 701 702

BTP Case Study

BTP 2. Task Time for 401, 402,
403, 404
402

311 401 403 404 501

T400 = Max (T402 ,T401+T403+T404) = Max (255, 15+31+45)

= Max (255, 91) = 255 sec.

But you need to check the probability that manual task time
! (T401+T403+T404) might be > the automated testing (T402)

BTP Case Study

BTP preliminary evaluation (steps 2-3-4)

Total task time: ti = 1445 sec

(operations 401, 403 and 404 are not considered because they are
carried out in hidden time)
10% of the
time is lost for
Cycle time [sec/piece]: inefficiencies

CT= (220 days/year x 8 h/day x 3.600 sec/h) x 0,9/ 25.000 =

= 228 sec/piece (3,8 min/piece)

Minimum number of stations:

K* = T/(CT x )= 1445/(228 x 0,95) = 7
Hypothesis: level
of utilization is
95%
BTP Case Study 8
BTP 5. Operations to stations
Opening of Station 1
Available operations: 101, 201, 301, 302, 303
Assignment of operations 101 to station 1 (first rule)
Evaluation of the utilization rate:

t101/CT = 55/228=0,24<0,95
Available operations: 102, 201, 301, 302, 303
Assignment of operation 102 to station 1 (first rule)
Evaluation of the utilization rate:

(t101+ t102 )/CT = (55+159)/228=0,94<0,95

I stop because adding any other operation to the station will pass the
maximum utilization rate
TOTAL TIME: 214 sec IDLE TIME: 14 sec

BTP Case Study 9

BTP 5. Operations to stations
301

303 304 305 306 307 308 309

310
Station 1
101 102 311 302

201 202 203 204 205 402

401 403 404

501 502 503 601 602 603 701 702

BTP Case Study 10

BTP 5. Operations to stations
Opening of Station 2
Available operations: 201, 301, 302, 303
Assignment of operation 302 (first rule) and then 201 to station 2
Evaluation of the utilization rate:

(t302+t201)/CT = 53/228=0,23<0,95
Assignment of operations 202, 203, 204, 205, 301 to station 2
Evaluation of the utilization rate:

(t201+ t202 + t203 + t204 + t205 + t301 + t302 )/CT =

(25+35+55+31+22+14+28)/228=210/228=0,92<0,95
I stop because adding new operations to the station will pass the maximum
utilizzation rate
TOTAL TIME: 210 sec IDLE TIME: 18 sec

BTP Case Study 11

BTP 5. Operations to stations
301

303 304 305 306 307 308 309

310
Station 1
101 102 311 302
Station 2
201 202 203 204 205 402

401 403 404

501 502 503 601 602 603 701 702

BTP Case Study 12

BTP 5. Operations to stations
Opening of Station 3
Available operations: 303
Assignment of operations 303 to station 3
Evaluation of the utilization rate:

t303/CT = 14/228=0,06<<0,95
Assignment of operation 304, 305, 306 to station 3
Evaluation of the utilization rate:

(t303+ t304 + t305 + t306 )/CT =

(14+96+46+17)/228=173/228=0,76<0,95

If also operation 307 is added: 173 + 78 =251>228, so I will not add it

TOTAL TIME: 173 sec IDLE TIME: 55 sec

BTP Case Study 13

Maximum operator utilization
301

303 304 305 306 307 308 309

Station 3 310
Station 1
101 102 311 302
Station 2
201 202 203 204 205 402

401 403 404

501 502 503 601 602 603 701 702

BTP Case Study 14

BTP 5. Operations to stations
Opening of Station 4
Available operations: 307
Assignment of operations 307 to station 4
Evaluation of the utilization rate:

t307/CT = 78/228=0,34<0,95
Assignment of operation 308,309,310 to station 4
Evaluation of the utilization rate:

(t307+ t308 + t309 + t310 )/CT =

(78+37+63+21)/228=199/228=0,87<0,95

If also operation 311 is added: 199 + 50 =249>228, so I dont add it

TOTAL TIME: 197 sec IDLE TIME: 31 sec

BTP Case Study 15

BTP 5. Operations to stations
301
Station 4
303 304 305 306 307 308 309

Station 3 310
Station 1
101 102 311 302
Station 2
201 202 203 204 205 402

401 403 404

501 502 503 601 602 603 701 702

BTP Case Study 16

BTP 5. Operations to stations
Opening of Station 5
Available operations: 311
Assignment of operations 311 to station 5
Evaluation of the utilization rate:

t311/CT = 50/228=0,22<0,95
Assignment of operations belonging to step 4:
Op. 401, 402, 403 and 404 are to be assigned to the same station
since op.401, 403 and 404 are performed in hidden time while the
product is on the testing machine

BTP Case Study 17

BTP 5. Operations to stations
PROBLEM: Time requested by the testing machine is higher than the
requested CT (255>228)
SOLUTION: In order to not exceed the CT, parallel stations could be
used.

Operations assigned to each station can take up to 2*CT = 2*228 =

456 sec
(t311+ t402)/(2*CT)= (50 + 255)/456 =0,67<0,95
Operations 501, 502, 503 can be added:
(t311+ t402 + t501 + t502 + t503 )/(2*CT)= (50+255+16+86+20)/456
=0,94<0,95
TOTAL TIME: 433 sec IDLE TIME: 23 sec

BTP Case Study 18

BTP 5. Operations to stations

Station 5a
402
311 401 403 404 501 502 503

Station 5b
402
311 401 403 404 501 502 503

BTP Case Study 19

BTP 5. Operations to stations
301
Station 4
303 304 305 306 307 308 309

Station 3 310
Station 1
101 102 311 302
Station 2
201 202 203 204 205 402

401 403 404

Station 5a/b

501 502 503 601 602 603 701 702

BTP Case Study 20

 BTP 5. Operations to stations
Opening of Station 6
Available operations: 601
Assignment of operations 601 and then 602, 603 to station 6
Evaluation of the utilization index:

(t601 + t602 + t603 )/CT = (6+44+33)/228=83/228=0,36<0,95

Assignment of operation 701, 702 to station 6
Evaluation of the utilization index:

(t601 + t602 + t603 + t701)/TC = (6+44+33+22)/228=99/228=0,43<0,95

A new station is needed for operation 702, because by adding it, the maximum
utilization rate is passed(TOTAL TIME: 99 s IDLE TIME: 129 s)
Station 7: t702= 119/228=0,52<0,95
TOTAL TIME: 119 sec IDLE TIME: 109 sec

BTP Case Study 21

BTP 5. Operations to stations
301
Station 4
303 304 305 306 307 308 309

Station 3 310
Station 1
101 102 311 302
Station 2
201 202 203 204 205 402

401 403 404

Station 5a/b Station 6

501 502 503 601 602 603 701 702 Station 7

BTP Case Study 22
BTP 5. Operations to stations
Recap:
CT

BTP Case Study 23

BTP Probability of no-completion

RTk = CT t
iS
i

where
CT = cycle time
ti = mean time to perform task i
S = set of tasks assigned to the operator
(task k included)

RT k
Zk =

iS
i
2

where
i = standard deviation of the time
required to perform task i

BTP Case Study 24

 BTP Probability of no-completion

Station 1:
RTk=228- (55+159) RTk=228-214=14
S1012 +S1022= 92+102=181
Zk= 14/181=1,04
(1,04)=0,85 1- (1,04)=0,15
Probability of no completion: 15%>7%

BTP Case Study 25

BTP Probability of no-completion

Station 2:
RTk=228-(25+35+55+31+22+14+28)= 228-210=18
S2012 +S2022 +S2032 +S2042 +S2052 +S3012 +S3022 = =32+42 +82 +42
+42 +22 +32 =134
Zk= 18/134=1,55
(1,55)=0,94 1- (1,55)=0,06
Probability of no completion: 6%<7%
Station 3:
RTk=228-(14+96+46+17)= 228-173=55
S3032 +S3042 +S3052 +S3062 =22+122 +52 +32 =182
Zk= 55/182=4,07
(4,07) 1
Probability of no completion: 0%<7%
BTP Case Study 26
BTP Probability of no-completion

Station 4:
RTk=228-(78+35+63+21)=228-197=31
S3072 +S3082 +S3092 +S3102 = 112+62 +92 +32 =247
Zk= 31/247=1,97
(1,97)=0,97 1- (1,97)=0,03
Probability of no completion: 3%<7%
Station 5:
RTk=456-(50+255+16+86+20)=456-427=29
S3112 +S4022 +S5012 +S5022 +S5032 = 72+22 +82 +52 =142
Zk= 29/142=2,43
(2,43) 0,99
Probability of no completion: 1%<7%

BTP Case Study 27

BTP Probability of no-completion

Station 6:
RTk=228-(6+44+33+22)=228-105=123
S6012 +S6022 +S6032 +S7012 = 12+32 +62 +32 =55
Zk= 123/55=16,58
(16,58) 1 Probability of no completion: 0%<7%

Station 7:
RTk=228-119=109
S7022 =49
Zk= 109/49=15,57
(15,57) 1 Probability of no completion: 0%<7%

BTP Case Study 28

BTP Considerations

The upper bound value of probability is exceeded

only in station 1.
Reduce the variance of 101 and 102 (if possible)
or
Redesign the line (e.g. growing from the first stations to the last
ones; other rules for task prioritization)
Its possible to balance again the line with MPno-C
(max probability of no completion, i.e. Pk<P)
method and then evaluate that the operator
utilization rate is respected
BTP Case Study 29
BTP An alternative solution

STATION 1: operations 101, 201, 202, 203, 204

STATION 2: operations 102, 205, 301

STATION 3: operations 302, 303, 304, 305

STATION 4: operations 306, 307, 308, 309

STATION 5: 310, 311, 401, 402, 403, 404, 501, 502,503

STATION 6,7 like in the previous solution

BTP Case Study 30

BTP Further clues for discussion

Is the line flexible enough to allow a

volume increasing?

BTP Case Study 31