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Balance 1
Assembly analysis
Assembly Chart
It shows the sequence of operations in putting
the product together. Using the exploded drawing
and the parts list, the layout designer will diagram
the assembly process.
Balance 3
Time Standards Are Required for Every Task
Balance 4
Plant Rate and Conveyor Speed
Example:
Charcoal grill are in cartons 30X30X24 inches
high. A total of 2,400 grills are required every
day.
Balance 5
Plant Rate and Conveyor Speed
Balance 6
Assembly line balancing
The purpose of the assembly line balancing technique is:
1. Cost of balancing
Subassemblies that cost too high can be taken off the
line.
Balance 10
Assembly line balancing
Balance 11
Assembly line balancing
Balance 12
Assembly line balancing
Balance 13
Assembly line balancing
Balance 15
Step-by-step procedure for completing the
assembly line balancing form
9. R value
The R value goes behind each operation. The plant rate is the
goal of each workstation, and by putting the R value on each
line (operation), one keeps that goal clearly in focus.
Balance 17
Step-by-step procedure for completing the
assembly line balancing form
In Figure 4-11, the average cycle times reveals that .167 is the
largest number and is designated the 100 percent workstation.
The percentage load of every other workstation is determined by
dividing .167 into every other average cycle time:
and so on.
Balance 18
Step-by-step procedure for completing the
assembly line balancing form
.167
h.p.u. .00278 hour per unit
60
The .167 time standard is for one person, if considering the people
number, the hour per unit will be:
Two people = .00557 hour per unit
Three people = .00835 hour per unit
Four people = .01113 hour per unit
Balance 19
Step-by-step procedure for completing the
assembly line balancing form
or
Sum of hours per unit
Line efficiency 100%
Sum of hours per unit line balance
Da
Rp
50 S w H sh
Balance 22
Analysis of single model assembly lines
60 E
Tc
Rp
Balance 23
Analysis of single model assembly lines
60
Rc
Tc
Balance 25
Analysis of single model assembly lines
60 ETwc
WL
Tc
The available time in the period, AT. AT = 60E
Tc
If we assume one worker per station, then this ratio also
gives the theoretical minimum number of workstations on
the line.
Balance 26
Analysis of single model assembly lines
Example
A small electrical appliance is to be produced on a single
model assembly line. The work content of assembling the
product has been reduced to the work elements listed in
table below along with other information. The line is to be
balanced for an annual demand of 100,000 units per year.
The line will be operated 50 weeks/yr, 5 shifts/wk, and 7.5
hrs/shift. Manning level will be one worker per station.
Previous experience suggests that the uptime efficiency for
the line will be 96%, and repositioning time lost per cycle
will be 0.08 min. Determine (a) total work content time
Twc, (b) required hourly production rate Rp to achieve the
annual demand, (c) Cycle time, and (e) service time Ts to
which the line must be balanced.
Balance 27
Analysis of single model assembly lines
Example
Balance 28
Analysis of single model assembly lines
Example
Balance 29
Analysis of single model assembly lines
Solution:
(a) The total work content time is:
Twc = 4.0 min.
60(0.96)
TC 1.08 min .
53.33
Balance 30
Analysis of single model assembly lines
Solution:
(d) The theoretical minimum number of workers is given by:
Twc
w* min int 3.7 4
Tc
(e) The average service time against which the line must
be balanced is:
Balance 31
Analysis of single model assembly lines
(1) T
k i
ek Ts
and
Balance 33
Largest Candidate Rule
Balance 35
Largest Candidate Rule
Solution:
The largest candidate algorithm is carried out as presented
in table below. 5 workers and stations are required in the
solution. Balance efficiency is computed as:
Twc 4.0
E 0.8
wTs 5(1.0)
Balance 36
Largest Candidate Rule
Work elements assigned to stations by LCR
Balance 37
Analysis of single model assembly lines
Example
Balance 38
Analysis of single model assembly lines
Balance 39
Analysis of single model assembly lines
Balance 40
Analysis of single model assembly lines
Ranked positional
Largest Candidate Kilbridge and
weights
Rule Wester method
Balance 41
Analysis of single model assembly lines
Balance 42