Keseimbangan Lintasan

Various Objects
 Part: is composed of a single material and is an individual      

part of the product Component: ranges from a part to a combination of parts which are included in the product Building block: a composite part of the product which because of assembly requirements represents a subassembly Base component: a (larger) component onto which others are assembled Formless material: e.g. viscose components such as glue, paint, liquids Sub-assembly: one component is assembled with another component, a base component or building block Final assembly: describes the construction of a building block or the finished product

Assembly Example

Exploded Assembly

The assembly of a joint

The concept of sub and final assembly

Step by step assembly

An integrated approach

Fabrication/Assembly Line

Fabrication/Assembly Line
 A production/fabrication line builds components on a     

series of machines An assembly line puts the fabricated parts together at a series of workstations Both are repetitive processes and in both cases, the line must be balanced Fabrication lines tend to be machine-paced and require mechanical and engineering changes to facilitate balancing Assembly lines tend to be paced by work tasks assigned to individuals or workstations Assembly lines therefore can be balanced by moving task form one individual or workstation to another. In this manner, the amount of time required by each individual or workstation is equalized

Assembly Line Balancing

 Assembly line is a production line in which material moves

  

continuously at a uniform average rate through a sequence of workstations where assembly work is performed Assembly accounts for between 40-60% of the total production time Down time of an assembly line costs a major car manufacturer $98,000 per minute Line balancing is usually done to minimize imbalance between individual/machine/workstation while meeting a required output from the line Problems in assembly lines: balancing the workstations and keeping the assembly line in continuous production

Types of assembly line balancing problems

 Simple assembly line balancing type I (SALB-I):

is to determine the minimal number of workstations necessary to maintain the production rate (1/CT) while observing the precedence constraints  Simple assembly line balancing type II (SALB-II): is to assign task to a fixed number of workstations to maximize the production rate while observing the precedence constraints  SALB-I is a more common problem than SALB-II

Definitions(1)
 Assembled product: the product that passes through a

    

sequence of workstations where tasks are performed on the product until it is completed at the final workstation. The throughput of the assembly line is measured by the number of assembled products per unit time Work element: a part of the total work content in an assembly process. N: The total number of work elements required to complete the assembly i: the work element number in the process (1i N) Workstation (WS): a location on the assembly line where a work element or elements are performed on the product. K denotes the minimum number of workstations, K1

Definitions(2)
 Cycle time (CT): the time between the completion of 2

   

successive assemblies, assumed constant for all assemblies for a given conveyor speed. Conveyors are the key material movers in most assembly lines: belt, chain, overhead, pneumatic, and screw conveyors T= production time available per day d= demand per day or production per day Station time (ST): the sum of the times of work elements that are performed at the same workstation. STCT Delay/idle time of a workstation: the difference between the cycle time (CT) and the station time (ST). D=CT-ST

Definitions(3)
 The number of work stations

 Precedence diagram: a diagram that describes the

ordering in which work elements should be performed. It shows that some jobs cannot be performed unless their predecessors are completed. The layout of workstations along the assembly line depends on the precedence diagram

Definitions(4)
 Perfect balance means to combine the elements of work to be

done in such a manner that at each station the sum of the elemental times just equals the cycle time (D=CTST=0)  Line efficiency (LE): the ratio of total station time to the cycle time multiplied by the number of workstations STi =the time for station I

 Smoothness index (SI): an index to indicate the relative

smoothness of a given assembly line balance. A smoothness index of zero indicates a perfect balance

Definitions(5)
 SI is expressed as

 Restrictions in designing an assembly line: Precedence relationship The number of workstations cannot be greater than the number of work elements (operations). The minimum number of workstations is 1. (1i N) The cycle time is greater than or equal to the maximum time of any station time and of the time of any work element ti. The station time should not be exceed the cycle time. tiSTiCT

Contoh 1
 Diketahui precedence diagram berikut:

Kilbridge-Weston Heuristic(1)
 1. Gambarkan precedence diagram. Bagi elemen-

elemen kerja dalam diagram tersebut ke dalam kolom-kolom. Kolom I adalah elemen-elemen kerja yang tidak memiliki elemen kerja pendahulu (predecessor). Kolom II adalah elemen-elemen kerja dengan elemen kerja pendahulu di Kolom I. Kolom III adalah elemen-elemen kerja dengan elemen kerja pendahulu di Kolom II, dan seterusnya.

Kilbridge-Weston Heuristic(2)

Kilbridge-Weston Heuristic(3)
 2. Tentukan waktu siklus (CT) dari bilangan prima waktu

total elemen kerja , dan tentukan jumlah stasiun kerja = 50

 Bilangan prima untuk 50 adalah 2 x 5 x 5, sehingga

alternatif waktu siklus adalah: 2, 5, 10, 25 dan 50. Alternatif waktu siklus mana yang tidak mungkin?  CT=2 dan CT=5 Kenapa?  Karena syarat: 7CT 50  Bila dipilih CT=10, maka jumlah stasiun kerja minimum adalah 50/10 = 5

Kilbridge-Weston Heuristic(4)
 3. Tempatkan elemen-elemen kerja ke stasiun

kerja sedemikian sehingga total waktu elemen kerja tidak melebihi waktu siklus. Hapus elemen kerja yang sudah ditempatkan dari daftar elemen kerja  4. Bila penempatan suatu elemen kerja mengakibatkan total waktu elemen kerja melebihi waktu siklus maka elemen kerja tersebut ditempatkan di stasiun kerja berikutnya  5. Ulangi Langkah 3 dan 4 sampai seluruh elemen kerja ditempatkan

Kilbridge-Weston Heuristic(5)

Kilbridge-Weston Heuristic(6)
 Untuk menjalankan Langkah 3 pada Metoda Kilbridge-

Weston, hitung jumlah elemen kerja pendahulu untuk setiap elemen. Elemen dengan jumlah pendahulu terkecil ditempatkan terlebih dahulu.

 Tempatkan Elemen 1 di Stasiun

1, kemudian Elemen 2 atau 4. Bila dipilih Elemen 2 maka jumlah total waktu elemen adalah 8. Elemen 4 tidak bisa ditempatkan ke Statsiun 1 karena akan menyebabkan total waktu elemen 11, yang melebihi CT

Kilbridge-Weston Heuristic(7)
 Elemen 4 kemudian ditempatkan di Stasiun 2.

Lanjutkan langkah ini untuk elemen dengan jumlah pendahulu terkecil berikutnya sampai seluruh elemen ditempatkan.

LE = 50/(6x10) = 83.3%

SI = 4 = 2

Kilbridge-Weston Heuristic(8)
 Dengan coba-coba dapat diperoleh alternatif

berikut:

LE = 50/(6x10) = 83.3%

SI = 4 = 2