D 0854

Supply Chain : Manufacturing and Warehousing

Session 18 Layout Design Production Line Balancing. .

Bina Nusantara University

Bina Nusantara University

Assembly Line Balancing

Assembly line balancing is traditionally thought of as a facilities design and layout problem There are a variety of factors that contribute to the difficulty of the problem
Precedence constrains: some tasks may have to be completed in a particular sequence Zoning restriction: Some tasks cannot be performed at the same workstation

Let t1, t2, , tn be the time required to complete the respective tasks

Assembly Line Balancing

The total work content (time) associated with the production of an item, say T, is given by n

T = ti
i= 1

For a cycle time of C, the minimum number of workstations possible is [T/C], where the brackets indicate that the value of T/C is to be rounded to the next larger integer Ranked positional weight technique: the method places a weight on each task based on the total time required by all of the succeeding tasks. Tasks are assigned sequentially to stations based on these weights

Assembly Line Balancing

Example 8.11 The Final assembly of Noname personal computers, a generic mail-order PC clone, requires a total of 12 tasks. The assembly is done at the Lubbock, Texas, plant using various components imported from the Far East. The network representation of this particular problem is given in the following figure.

Precondition
The job times and precedence relationships for this problem are summarized in the table below.

Task
1 2 3 4 5 6 7 8 9 10 11 12

Immediate Predecessors
_ 1 2 2 2 2 3, 4 7 5 9, 6 8, 10 11

Time
12 6 6 2 2 12 7 5 1 4 6 7

Assembly Line Balancing: Helgeson and Birnie Heuristic (1961)

Ranked positional weight technique The solution precedence requires determining the positional weight of each task. The positional weight of task i is defined as the time required perform task i plus the times required to perform tasks having task i as a predecessor.
Task Time 12 6 6 2 2 12 7 5 1 4 6 7

to all

t3 + t7 + t8 + t11 + t12 = 31

Positional Weight 70 58 31 27 20 29 25 18 18 17 13 7

1 2 3 4 5 6 7 8 9

The ranking: 1, 2, 3, 6, 4, 7, 5, 8, 9, 10, 11, 12 ti = 70, and the production rate is a unit per 15 minutes; The minimum number of workstations = [70 / 15] = 5

10 11 12

Assembly Line Balancing: Helgeson and Birnie Heuristic (1961)

Station Tasks Processing time Idle time 1 1 12 3 2 2, 3, 4 14 1 3 5, 6, 9 15 0 4 7, 8 12 3 5 10, 11 10 5 6 12 7 8

Task 1 2 3 4 5 6 7 8 9 10 11 12

Immediate Predecessors _ 1 2 2 2 2 3, 4 7 5 9, 6 8, 10 11

Time 12 6 6 2 2 12 7 5 1 4 6 7

C=15

The ranking: 1, 2, 3, 6, 4, 7, 5, 8, 9, 10, 11, 12

Helgeson and Birnie Heuristic (1961)

C=15
Station Tasks Processing time Idle time 1 1 12 3 2 2,3,4 14 1 3 5,6,9 15 0 4 7,8 12 3 5 10,11 10 5 6 12 7 8

15 Cycle Time=15 T1=12 T2=6 T5=2 T7=7 T10=4 T12=7 T3=6 T6=12 T8=5 T11=6 T2=6 T4=2 T5=2 T9=1 T10=4 T12=7

Evaluate the balancing results by the efficiency ti/NC The efficiencies for C=15 is 77.7%, C=16 is 87.5%, and C=13 is 89.7% is the best one

Helgeson and Birnie Heuristic (1961)

C=15
Station Tasks Processing time Idle time 1 1 12 3 2 2,3,4 14 1 3 5,6,9 15 0 4 7,8 12 3 5 10,11 10 5 6 12 7 8

C=16
Station Tasks Idle time 1 1 4 2 2,3,4, 5 0 3 6,9 3 4 7,8,10 0 5 11,12 3

C=13
Station Tasks Idle time 1 1 1 2 2,3 1 3 6 1 4 4,5,7,9 1 5 8,10 4 6 11,12 0

Increasing the cycle time from 15 to 16, the total idle time has been cut down from 20 min/units to 10 improvement in balancing rate. The production rate has to be reduced from one unit/15 minutes to one unit/16minute;

Helgeson and Birnie Heuristic (1961)

C=15
Station Tasks Processing time Idle time 1 1 12 3 2 2,3,4 14 1 3 5,6,9 15 0 4 7,8 12 3 5 10,11 10 5 6 12 7 8

C=16
Station Tasks Idle time 1 1 4 2 2,3,4, 5 0 3 6,9 3 4 7,8,10 0 5 11,12 3

13 minutes appear to be the minimum cycle time with six station balance. Increasing the number of stations from 5 to 6 results in a great improvement in production rate;

C=13
Station Tasks Idle time 1 1 1 2 2,3 1 3 6 1 4 4,5,7,9 1 5 8,10 4 6 11,12 0

Stochastic Scheduling: Static Case

Single machine case: Suppose that processing times are random variables. If the objective is to minimize average weighted flow time, jobs are sequenced according to expected weighted SPT. That is, if job times are t1, t2, . . ., and the respective weights are u1, u2, . . . then job i precedes job i+1 if E(ti)/ui < E(ti+1)/ui+1 Multiple Machines: Requires the assumption that the distribution of job times is exponential, (memoryless property). Assume parallel processing of n jobs on two machines. Then the optimal sequence is to to schedule the jobs according to LEPT (longest expected processing time first). Johnsons algorithm for scheduling n jobs on two machines in the deterministic case has a natural extension to the stochastic case as long as the job times are exponentially distributed.

Stochastic Scheduling: Queueing Theory

A typical queueing process

Customers arriving

Served customers leaving

Service Facility

Discouraged customers leaving

The basic phenomenon of queueing arises whenever a shared facility needs to be accessed for service by a large number of jobs or customers. (Bose) The study of the waiting times, lengths, and other properties of queues. (Mathworld)

Applications: Telecommunications Health services Traffic control Predicting computer performance Airport traffic, airline ticket sales Layout of manufacturing systems Determining the sequence of computer operations

Examples of Queueing Theory

http://www.bsbpa.umkc.edu/classes/ashley/Chaptr14/sld006.htm

Stochastic Scheduling: Dynamic Analysis

View network as collections of queues
FIFO data-structures

Queuing theory provides probabilistic analysis of these queues Typical operating characteristics of interest include:
Lq = Average number of units in line waiting for service L = Average number of units in the system (in line waiting for service and being serviced) Wq = Average time a unit spends in line waiting for service W = Average time a unit spends in the system Pw = Probability that an arriving unit has to wait for service Pn = Probability of having exactly n units in the system P0 = Probability of having no units in the system (idle time) U = Utilization factor, % of time that all servers are busy

Characteristics of Queueing Processes

Arrival pattern of customers Service pattern of servers Queue discipline System capacity Number of service channels Number of service stages

Characteristics of Queueing Processes

Arrival pattern of customers
Probability distribution describing the times between successive customer arrivals

Time independent Stationary arrival patterns Time dependent Non-stationary

Batch or Bulk customer arrivals

Probability distribution describing the size of the batch

Customers behavior while waiting

Wait no matter how long the queue becomes If the queue is too long, customer may choose not to enter into the system Enter, wait, and choose to leave without being serviced If there is more than one waiting line, customer may switch jockey

Characteristics of Queueing Processes

Arrival pattern of customers Service pattern of servers
Single or Batch May depend on the number of customers waiting state dependent Stationary or Non-stationary

Queue discipline
Manner in with customers are selected to service First Come First Served (FCFS) Last Come First Served (LCLS) Random Selection for Service (RSS) Priority Schemes

Preemptive case Non-preemptive case

Characteristics of Queueing Processes

Arrival pattern of customers Service pattern of servers Queue discipline System capacity Finite queueing situations = Limiting amount of waiting room

Number of service channels Single-channel system

Multi-channel system, generally assumed that parallel channels operate independently of each other

Number of service stages

Notation Used in Queueing Processes

Full notation: A/B/X/Y/Z Shorthand: A/B/X

A indicates the interarrival-time distribution B the probability distribution for service time X number of parallel service channels Y the restriction on system capacity Z the queue discipline (FCFS)

Assumes: Y is infinity, Z = FCFS

Symbol = Explanation A B X Y Z M = Exponential, D = Deterministic, Ek = Erlang type Hk = Mixture of k exponentials, PH = Phase type, G = General 1, 2, ... , infinity 1, 2, ... , infinity FCFS, LCLS, RSS, PR = priority, GD = general discipline

Queueing Processes: Littles Formulas

One of the most powerful relationships in queueing theory was developed by John D.C. Little in the early 1960s. Formulas:

where is an average rate of customers entering the system, and W is an expected time customer will spend in the system

L = W

and

Lq = Wq

Number of customers in system 3 2 1 t1 t2 t3 t4 t5 t6 t7 T Time, t

Poisson Process & Exponential Distribution

M: stands for "Markovian", implying exponential distribution for service times or inter-arrival times, that carries the memoryless property
past state of the system does not help to predict next arrival / departure

n-1

n+1

Calculating Expected System Measures for M/M/1 0 1 2 SYMBOL L Lq W=L/ Wq=Lq/ P0 FORMULA / / ( ) = / (1-) 2/ ( ) = 2 / (1-) 1 / ( ) = / (1-) / ( ) = 2 / (1-) 1 ( / ) = 1 -
The utilization rate: = / P0 = 1 Pi = i(1 ), for i = 1, 2, 3, these formulas hold only if <

CHARACTERISTIC Utilization Exp. No. in System Exp. No. in Queue Exp. Waiting Time Exp. Time in Queue Prob. System is Empty

Calculating Expected System Measures for M/M/m

http://www.ece.msstate.edu/~hu/courses/spring03/notes/note4.ppt

Calculating Expected System Measures for M/M/m

Assumption - m servers - all servers have the same service rate - single queue for access to the servers - arrival rate n = - departure rate

n , n = 0, 1, 2, , ( m 1) n = m , n = m, ( m + 1) ,

2 m-1

0 1

m+1

(m-1)

Calculating Expected System Measures for M/M/m

( m ) ( m ) P0 = + m! n=0 n!
m 1 n 1

(1 )

m m m+1 Lq = P 2 0 m!(1 )

W = Wq + 1

0 1

Wq = Lq

L = Lq + m

m-1 m

m+1

3 (m-1)

Example
Unisex hair salon runs on a first-come, first-served basis. Customers seem to arrive according to a Poisson process with mean arrival rate of 5/hr. Because of Ms. H.R. Cutts excellent reputation, customers are always willing to wait. Average service time of 10 min is exponentially distributed. Calculate the average number of customers in the shop and the average number of customers waiting for a haircut. Calculate the percentage of time an arrival can walk right in without having to wait at all. The waiting room has only 4 seats. What is the probability that a customer upon arrival rill have to stand? Calculate average system waiting time, and the line delay.

Other Systems M/M/1/K - system with a capacity K eff = effective arrival rate M/D/1; M/G/1; M/G/

Assignment: download the QTS add-in for Excel software to check the homework problems answers http://www.geocities.com/qtsplus/DownloadInstructions.htm#DO WNLOAD_INSTRUCTIONS