Line Balancing in Operations Management

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Definition:

Line balancing is the procedure in which tasks along the assembly line are assigned to work station so each has approximately same amount of work.

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Line Balancing Problem

The objective of line balancing is to assign tasks to minimize the workers idle time, therefore idle time costs, and meet the required production rate for the line In a perfectly balanced line, all workers would complete their assigned tasks at the same time (assuming they start their work simultaneously)

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Line Balancing Problem

Unfortunately there are a number of conditions that prevent the achievement of a perfectly balanced line
The estimated times for tasks The precedence relationships for the tasks The combinatorial nature of the problem

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Line Balancing Problem

Work stations are arranged so that the output of one is an input to the next, i.e., a series connection

Layout design involves assigning one or more of the tasks required to make a product to work station.

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Example of Line Balancing

Youve just been assigned the job a setting up an electric fan assembly line with the following tasks:
Time (Mins) 2 1 3.25 1.2 0.5 1 1 1.4 Description Assemble frame Mount switch Assemble motor housing Mount motor housing in frame Attach blade Assemble and attach safety grill Attach cord Test Predecessors None A None A, C D E B F, G

Task A B C D E F G H

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Example of Line Balancing: Structuring the Precedence Diagram

Task Predecessors A None B A C None Task Predecessors E D F E G B

A, C
2

H
1 1

E, G
1.4

A
3.25

B
1.2

G H
0.5 1

F
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Kilbridge and Webstor Method

Step 1- draw a precedence diagram and arrange them into different zones so that the average time is equal or nearly equal.

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Line Balancing Problem

3.4 mins B 2.2 mins A E

C
4.1mins D 1.7mins F

2.7 mins

3.3 2.6 mins mins Visit www.mbaknol.com for

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Here idle time=16.8 idle time %age=(16.8/9.2)X100=182.60% This is not acceptable

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Step 2- transferability; in this principle the activities are transferred from one zone to another as long as they dont affect the sequence denoted by ordered pair

.Step 3- from step 2 and by arranging

the work centres, the lines balancing becomes
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Line Balancing Problem

3.4 mins B 2.2 mins A E

C
4.1mins D 1.7mins F

2.7 mins

3.3 2.6 mins mins Visit www.mbaknol.com for

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here idle time=4 min idle time %age=(4/6)X100=66.6%

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Thank You

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