ASSEMBLY LINE BALANCING

Task Time(sec)
Description
A
2
Placing Cabinet-front on Conveyor
B
3
Mounting Picturetube on Cabinet
C
5.5
Screwing of Picture tube with Cabinet-4 screws
D
2
Chassis insertion
E
3.5
Assemble picture tube with Chassis
F
5.5
White Balancing
G
5.5
Picture Quality Checking
H
5.5
Sound Quality Checking
I
2.5
Back Cabinet Docking
J
3.25
Screwing of Back Cabinet with Cabinet Front-7 screws
K
4
Putting Bag Pe & Thermocol
L
3.5
Putting in Box

2.2

Box Sealing with Cello Tape

Predessesors
None
A
A,B
A
A,B,C,D
A,B,C,D,E
A,B,C,D,E,F
A,B,C,D,E,F
A,B,C,D,E,F,G
A,B,C,D,E,F,G,H
A,B,C,D,E,F,G,H,I
A,B,C,D,E,F,G,H,I,J

A,B,C,D,E,F,G,H,I,J,K

We want to assemble 5000 TV sets in a

days production

Production time per period

Required Cycle Time, C =
Required output per period

C=

28800 sec/day
= 5.76 sec/unit
5000 units/day

Question: What is the theoretical minimum

number of workstations for this problem?

Theoretical Min. Number of Workstations, N t

Sum of task times (T)
Nt =
Cycle time (C)

47.95sec/unit
Nt =
= 8.32, or 9
5.76 sec/unit

Complications
Behavioral options

Job enlargement and rotation.

Wages related to task.
Distribution of slack time.
Inventory buffers.
Involving work group in decisions.
Arranging stations to facilitate interaction.
Personnel selection.

Time to move an item between stations

Machine-dominated work stations.
Task times which exceed the cycle time.
Mixed model assembly lines.

5.5

TASKS FOLLOWERS TIME

A
11
2
B
8
3
C
8
5.5
D
8
2
E
7
3.5
F
6
5
G
6
5.5
H
5
5
I
4
4
J
3
5.5
K
2
4.5
L
1
3.5
M
0
5

5.5
G

3.5

5.5

4.5

3.5

H
5

5.5

TASKS FOLLOWERS TIME

A
11
2
B
8
3
C
8
5.5
D
8
2
E
7
3.5
F
6
5.5
G
6
5.5
H
5
5.5
I
4
2.5
J
3
3.25
K
2
4
L
1
3.5
M
0
2.2

5.5
G

3.5

5.5

4.5

3.5

H
5

Station
1

A
(5.76-2=3.76)
B
(3.76-3=.76)
Idle : 0.76

Station
2

Station
3

Station
4

Station
5

Station
6

Station
7

Station
8

Station
9

5.5

TASKS FOLLOWERS TIME

A
11
2
B
8
3
C
8
5.5
D
8
2
E
7
3.5
F
6
5.5
G
6
5.5
H
5
5.5
I
4
2.5
J
3
3.25
K
2
4
L
1
3.5
M
0
2.2

5.5
G

3.5

5.5

4.5

3.5

H
5

Station
1

Station
2

C
A
5.76-2=3.76 (5.76-5.5=.26
B
3.76-3=.76
Idle : 0.76

Idle : 0.26

Station
3

Station
4

Station
5

Station
6

Station
7

Station
8

Station
9

5.5

TASKS FOLLOWERS TIME

A
11
2
B
8
3
C
8
5.5
D
8
2
E
7
3.5
F
6
5.5
G
6
5.5
H
5
5.5
I
4
2.5
J
3
3.25
K
2
4
L
1
3.5
M
0
2.2

5.5
G

3.5

5.5

4.5

3.5

H
5

Station
1

Station
2

C
A
5.76-2=3.76 (5.76-5.5=.26
B
3.76-3=.76
Idle : 0.76

Idle : 0.26

Station
3

Station
4

Station
5

Station
6

Station
7

Station
8

Station
9

5.5

TASKS FOLLOWERS TIME

A
11
2
B
8
3
C
8
5.5
D
8
2
E
7
3.5
F
6
5.5
G
6
5.5
H
5
5.5
I
4
2.5
J
3
3.25
K
2
4
L
1
3.5
M
0
2.2

5.5
G

3.5

5.5

2.5

3.25

3.5

2.2

H
5.5

Station
1

Station
2

Station
3

Station
4

Station
5

Station
6

Station
7

Station
8

Station
9

D
C
A
D
G
K
L
H
I
5.76-2=3.76 5.76-5.5=.26 5.76-2=3.76 5.76-5.5=.26 5.76-5.5=.26 5.76-5.5=.26 5.76-2.5=3.26 5.76-4=1.76 5.76-3.5=2.26
B
E
M
J
3.76-3=.76
3.76-3.5=.26
2.26-2.2=.06
3.26-3.25=.01
Idle : 0.76

Idle : 0.26

Idle : 0.26

Idle : 0.26

Idle : 0.26

Idle : 0.26

Idle : 0.01

Idle : 1.76

Idle : 0.76

Sum of task times (T)

Efficiency =
Actual number of workstations (Na) x Cycle time (C)

47.95 sec/unit
Efficiency =
= .925 92.5%
(9)(5.76 sec/unit)

Balance delay = (1 - LE)

= 7.5%

Smoothness index

N
= (S Tmax - Sti)2
i=1

= (.762+.262+.262+.262+.262+.262+.012+1.762+.762
=

2.14