Line Balancing

Dr. Chanchala Jain

 Line Balancing Process
• Product layouts or assembly lines are used for high-
volume production. To attain the required output
rate as efficiently as possible, jobs are broken down
into their smallest indivisible portions, called work
elements.
• Work elements are so small that they cannot be
performed by more than one worker or at more
than one workstation. But it is common for one
worker to perform several work elements as the
product passes through his or her workstation.
• Part of the layout decision is concerned with
grouping these work elements into workstations so
products flow through the assembly line smoothly.
• A workstation is any area along the assembly line
that requires at least one worker or one machine.
• If each workstation on the assembly line takes the
same amount of time to perform the work elements
that have been assigned, then products will move
successively from workstation to workstation with
no need for a product to wait or a worker to be idle.
The process of equalizing the amount of work at
each workstation is called line balancing.
Requiring one worker Layout Decision
/ One workstation
Worker needs to
perform several work
WE1 elements Grouping
Work
of work
WE2 Station
elements
Job1
WE3
WE1
WE4
WE2
Job3
WE1 WE3 Time taken by WS1
= Equalizing the
WE2 WE4 Time taken by WS2 amount of work
Job2 =
Time taken by WS3
@ each work
WE3 station
.
WE4 . = Line balancing
WE = Work Element Time taken by WSn
WS = Work Station
Design Product Layouts: Line
Balancing

Line Balancing is the process of assigning

tasks to workstations in such a way that
the workstations have approximately
equal time requirements.
Objective of Line Balancing

To minimize the imbalance between

machines or personnel while meeting
required output
Or
To balance the assembly line by equalizing
the work at each workstation
 Line Balancing Process
1. Draw and label a precedence diagram.
2. Calculate the desired cycle time required for the
line.
3. Calculate the theoretical minimum no. of
workstations.
4. Group elements into workstations, recognizing
cycle time and precedence constraints.
5. Calculate the efficiency of line.
6. Determine if the theoretical minimum number of
workstations or an acceptable efficiency level has
been reached. If not, go back to step 4.
 Precedence Diagram
Precedence diagram: Tool used in line balancing to display
elemental tasks and sequence requirements

A Simple Precedence
0.1 min. 1.0 min. Diagram
a b

c d e
0.7 min. 0.5 min. 0.2 min.
 Cycle Time

Cycle time is the maximum time

allowed at each workstation to
complete its set of tasks on a
unit.
 Desired Cycle Production time available
Time =
Desired units of outputs

n
∑ ti Actual Maximum
i=1
N= Cycle = work station
Cd Time time
n
∑ ti Cycle Time = 1/Throughput rate
i=1
E=
nCa Where,
N = Minimum no. of workstations
Balance E = Efficiency
i = no. of work elements
Delay = 1 – Efficiency ti = completion time of element i
Cd = desired cycle time
Idle time = nc – t Ca = actual cycle time
n = actual no. of work stations
 Line Balancing Rules
Some Heuristic (intuitive) Rules:

• Assign tasks in order of most following

tasks.
–Count the number of tasks that follow
• Assign tasks in order of greatest positional
weight.
– Positional weight is the sum of each task’s
time and the times of all following tasks.
 Line Balancing Rules
Layout Heuristic that may be used to assign
tasks to workstations in Assembly-Line
Balancing
Longest Task From the available tasks, choose the task with
Time the largest (longest) task time

Most Following From the available tasks, choose the task with
Task the largest number of following tasks

Ranked From the available tasks, choose the task for

Positional which the sum of following task time is the
Weight longest
Shortest Task From the available tasks, choose the task with
Time the shortest task time
Least number of From the available tasks, choose the task with
following task the least number of subsequent tasks
Illustration 1
Real Fruit Snack Strips are made from a mixture of dried fruit,
fruit coloring, preservatives and glucose. The mixture is
processed out into a thin sheet, imprinted with various
shapes, rolled and packaged. The precedence and time
requirements for each step in the assembly process are given
below. To meet demand, Real Fruit needs to produce 6000
food strips every 40-hour week. Design an assembly line with
the fewest no. of workstations that will achieve the production
quota without violating precedence constraint.
Task Work Element Precedence Time (min)
A Press out sheet of - 0.1
fruit
B Cut into strips A 0.2
C Outline fun shape A 0.4
D Roll up and B, C 0.3
package
 Task Work Element Precedence Time (min)
A Press out sheet of - 0.1
fruit
B Cut into strips A 0.2
C Outline fun shape A 0.4
D Roll up and B, C 0.3
package

0.2

B Precedence
Diagram
0.1 A D 0.3

C
0.4
 Production time available 40 hours* 60 minutes/hour
Cycle Time = =
Desired units of outputs 6000 units

2400
= = 0.4 minutes
6000
n
∑ ti
i=1 0.1 + 0.2 + 0.4 + 0.3
N= = = 2.5 workstations ≈ 3 workstations
Cd 0.4

Workstation Work Element Remaining Remaining

Time Elements
1 A 0.3 B, C, D
B 0.1 C, D
2 C 0.0 D
3 D 0.1 None
 0.2

B Assembly line has

an efficiency of -
n
A D 0.3 ∑ ti
i=1
0.1 E=
nCa
C 0.1 + 0.2 + 0.4 + 0.3
0.4
=
3*0.4
1.0
Work Work Work = = 0.833 = 83.3%
1.2
station 1 station 2 station 3

A, B C D
0.3 minute 0.4 minute 0.3 minute
Illustration 2:
480 available minutes per day
40 units required
Task Precedence Time
A - 10
B A 11
C B 5
D B 4
E A 12
F C, D 3
G F 7
H E 11
I G, H 3
Total Time 66
 Precedence
4 Diagram
D
10 11 3 7

A B F G
5

C
12 11 3

E H I
 Production time available 480 minutes
Cycle Time = = = 12 minutes/unit
Desired units of outputs 40 units
n
∑ ti
i=1 66
N= = = 5.5 workstations ≈ 6 workstations
Cd 12

Workstation Work Element Remaining Remaining

Time Elements
1 A 2 B, C, D, E, F, G, H, I

2 B 1 C, D, E, F, G, H, I
3 C 7 E, G, H, I
D 3
F 0
4 E 0 G, H, I
5 G 5 H
I 2
6 H 1 None
 Work
station 3
Work Work 4
station 1 station 2
D
10 11 3 7

A B F G
5

C
12 3
11
E H I
Work Work Work
station 4 Station 6 Station 5
Assembly line has an efficiency of -
n
∑ ti
i=1
E=
nCa

66
=
6*12
66
= = 0.917 = 91.7%
72

Balance
Delay = 1 – Efficiency

Balance Delay = 1 – 0.917 = 0.083 or 8.3%

Illustration 3: Customer demand requires production volume
of 24 finished clubs in an 8 hours shift

Task Task Description Immediate Task Time

Predecessor (Minutes)
A Inspection None 5
B Trim the shaft to A 4
length
C Weight the head A 13
D Finish the shaft B 9
E Gel coat the head C 7
F Assemble the head to D, E 6
the shaft
Total Time 44
 Precedence Diagram
4 9

B D
5

A F 6

C E
13 7
 Production time available 8 hour*60 min/hr
Cycle Time = = = 20 minutes/club
Desired units of outputs 24 clubs
n
∑ ti
i=1 44
N= = = 2.2 workstations ≈ 3 workstations
Cd 20

Workstation Work Element Remaining Remaining

Time Elements
1 A 15 B, C, D, E, F
C 2 B, D, E, F
2 B 16 D, E,F
D 7 E, F
E 0 F
3 F 14 NONE
 Work
station 2

4 9
Work
station 1 B D Work
station 3

5
A F 6

Idle Time = 14 mins

C E
13 7
Idle Time = 0
Idle Time = 2 mins
Illustration 4: Vicki’s Pizzeria
Desired output = 60 units/hour
Time = 60 minutes
Work Task Description Immediate Task Time
Element Predecessor (Seconds)
A Roll dough None 50
B Place on cardboard A 5
backing
C Sprinkle cheese B 25
D Spread sauce C 15
E Add pepperoni D 12
F Add sausage D 10
G Add mushrooms D 15
H Shrink-wrap pizza E, F, G 18
I Pack in box H 15
Total Time 165
 Precedence Diagram

10
F
50 5 25 15 12 18
A B C D E H I
15
G
15
 Production time available 60 min/hour * 60 sec/min
Cycle Time = =
Desired units of outputs 60 units/hour
n
∑ ti = 60 sec/unit
i=1 165
N= = = 2.75 workstations ≈ 3 workstations
Cd 60

Workstation Eligible Task Task Time Idle Time

Task Selected
1 A A 50 10
B B 5 5
2 C C 25 35
D D 15 20
E, F, G G 15 5
3 E, F E 12 48
F F 10 38
H H 18 20
I I 15 5
 Workstations Work
station 3

Work
Work 10
station 2
station 1 F
50 5 25 15 12 18
A B C D E H I
15
Idle Time = 5 mins
G Idle Time = 5 mins

15
Idle Time = 5 mins
Illustration 5: The precedence diagram for a
assembly activities A to G is shown in table. The
elements times required for the activities are in
minutes. The line operates for 7 hours per day and
the output of 550 units per day is desired.
Calculate
• The cycle time and
• The theoretical minimum number of work
stations
• Group the tasks into an appropriate number
of work stations.
• Calculate the balance efficiency.
Activities Immediate Task Time
Predecessor (Minutes)
A None 0.65
B A 0.40
C B 0.30
D C 0.20
E C 0.45
F D, E 0.40
G F 0.30
Total Time 2.70
 Precedence Diagram
0.20

D
0.65 0.40 0.30 0.40 0.30

A B C F I

E
0.45
 Production time available 7 hours/day*60 minutes/hour
Cycle Time = =
Desired units of outputs 550 units/day
n
∑ ti = 0.76 min/unit
i=1 2.7
N= = = 3.55 workstations ≈ 4 workstations
Cd 0.76

Workstation Cycle Time Task Task Time Idle Time

Selected
1 0.76 A 0.65 0.11
2 0.76 B, C 0.40 + 0.30 0.06
= 0.70
3 0.76 D, E 0.20 + 0.45 0.11
= 0.65
4 0.76 F, G 0.40 + 0.30 0.06
= 0.70
 Work
station 3

0.20
Work
Work Work
station 2
station 1 D Station 4

0.65 0.40 0.30 0.40 0.30

A B C F I

Idle Time =
0.11 mins Idle Time =
0.06 mins
E Idle Time =
0.06 mins
0.45

Idle Time = 0.11 mins

 Illustration 6

Plan to produce 400 units in 1 day (8 hours)

Immediate Task time

Task Successor (min)
a b 0.2
b e 0.2
c d 0.8
d f 0.6
e f 0.3
f g 1.0
g h 0.4
h end 0.3
0.2 0.2 0.3

a b e

0.8 0.6

c d f g h
1.0 0.4 0.3
Station 1 Station 2 Station 3 Station 4

a b e
f g h
c d
 Illustration 7

EXAMPLE
Green Grass’s plant manager just received marketing’s latest
forecasts of fertilizer spreader sales for the next year. She
wants its production line to be designed to make 2,400
spreaders per week. The plant will operate 40 hours per week.

a. What should be the line’s cycle time or throughput rate per hour be?

Throughput rate/hr = 2400 / 40 = 60 spreaders/hr

Cycle Time = 1/Throughput rate= 1/60 = 1 minute = 60 seconds
 Continue….
Assume that in order to produce the new fertilizer spreader on the
assembly line requires doing the following steps in the order specified:

Work Immediate
Description Time (sec)
Element Predecessor(s)
A Bolt leg frame to hopper 40 None
B Insert impeller shaft 30 A
C Attach axle 50 A
D Attach agitator 40 B
E Attach drive wheel 6 B
F Attach free wheel 25 C
G Mount lower post 15 C
H Attach controls 20 D, E
I Mount nameplate 18 F, G
Total 244
b. What is the total number of stations or machines required?
TM (total machines) = total production time / cycle time = 244/60 = 4.067 or 5
 Draw a Precedence Diagram
SOLUTION
The figure shows the complete diagram. We begin with work element A,
which has no immediate predecessors. Next, we add elements B and C, for
which element A is the only immediate predecessor. After entering time
standards and arrows showing precedence, we add elements D and E,
and so on. The diagram simplifies
interpretation. Work element F,
for example, can be done D
H
anywhere on the line after B 40
20
element C is completed. 30 E
However, element I must 6
await completion of A
F
elements F and G. 40 C 25
50
I
18
G
Precedence Diagram for
15
Assembling the Big Broadcaster
 Allocating work or activities to
stations or machines
• The goal is to cluster the work elements into
workstations so that
1. The number of workstations required is minimized
2. The precedence and cycle-time requirements are not
violated

• The work content for each station is equal (or nearly so,
but less than) the cycle time for the line
• Trial-and-error can be used but commercial software
packages are also available
 Finding a Solution
• The minimum number of workstations is 5 and the
cycle time is 60 seconds, so following represents
an optimal solution to the problem

D
H
B 40
20
30 E
6
A
F
40 C
25
50
I
18
G
15

Fertilizer Precedence Diagram Solution

 Calculating Line Efficiency

c. Now calculate the efficiency measures of a five-station solution:

t 244
Efficiency = nc (100) = = 81.3%
5(60)

Balance delay (%) = 100 – Efficiency = 100% - 81.3% = 18.7%

Idle time = nc – t = 5(60) – 244 = 56 seconds

 Illustration 8
A plant manager needs a design for an assembly line to assembly a new
product that is being introduced. The time requirements and
immediate
predecessors for the Immediate
Work Element Time (sec)
Predecessor
work elements are
A 12 ―
as follows:
B 60 A
C 36 ―
D 24 ―
E 38 C, D
F 72 B, E
G 14 ―
H 72 ―
I 35 G, H
J 60 I
K 12 F, J
Total = 435
 Solution
Draw a precedence diagram, complete I, F, J, and K

Work Time (sec) Immediate

Element Predecessor
A
A 12 ―
B 60 A
B
C 36 ― C
D 24 ― F
E 38 C, D K
D E
F 72 B, E
G 14 ―
J

H 72 ―
G I
I 35 G, H
J 60 I H
K 12 F, J

Total = 435
 Solution

If the desired output rate is 30 units per hour, what are the cycle time
and theoretical minimum?

1 1
c= = (3600) = 120 sec/unit
r 30

t 435
TM = = = 3.6 or 4 stations
c 120
 Solution

Suppose that we are fortunate enough to find a solution with just four
stations. What is the idle time per unit, efficiency, and the balance delay
for this solution?

Idle time = nc – t = 4(120) – 435 = 45 seconds

t 435
Efficiency (%) = (100)
nc = (100) = 90.6%
480

Balance delay (%) = 100 – Efficiency = 100 – 90.6 = 9.4%

 Solution
Using trial and error, one possible solution is shown below.

Work
Elements Idle Time
Station Assigned Cumulative Time (c = 120)
1
2
3
4
5
 Solution
Using trial and error, one possible solution is shown below.

Work
Elements Idle Time
Station Assigned Cumulative Time (c = 120)
1 H, C, A 120 0
2 B, D, G 98 22
3 E, F 110 10
4 I, J, K 107 13
5 A fifth station is not needed
 Illustration 9

Calculate

I. Precedence diagram
ii. Theoretical no. of WS
iii. Line efficiency

CT = 0.70 min
Illustration 10: CT = 1 min