S K Mo

ondal Cha
apter 3

3. Line
e Ba
alanc
cing

The
eory at a Glance (F
For IES
S, GAT
TE, PSU
U)

Assem
A mbly Line
L Balan
ncing
g
In
ntroduc
ction
Ann assembly y line is a flow-orien nted producction system m where tthe producttive units
performing thhe operation ns, referred
d to as stattions, are aligned
a in a serial manner. The
woorkpiece visiit stations successively
s y as they aree moved aloong the line usually by some kind
of transportattion system,, e.g. a conv
veyor belt.

Objectiv
O ve in Lin
ne Bala
ancing Problem
m
In an assemb bly line, th
he problem is to desiggn the work k station. Each
E work station is
designed to co
omplete feww processing
g and assemmbly tasks. The objective in the deesign is to
assign processes and tassks to indiv
vidual statioons so that the total tiime requireed at each
woork station is approxim
mately samme and nearrer to the desired
d cycle time or production
p
ratte.
In case, all the work elem
ments which h can be grouped at any y station have same sta
ation time,
the
en this is a case of perrfect line ba ow would bee smooth in this case.
alancing. Prooduction flo
Hoowever, it isi difficult to achieve this in reeality. When n perfect line balanciing is not
hieved, the station tim
ach me of slowesst station woould determmine the prooduction ratte or cycle
tim
me.
Ex
xample: Let
L us conssider a fiv
ve-station assembly system in which the station
tim
mes are 12, 16, 13, 11 and 15 miinutes resppectively. The
T slowesst station is
i station
2, which takkes 16 min n., while station
s 4 is fastest with
w 11 miin. of statiion time.
Woork carrier
r enters att station: and
a leaves at station 5. Now a w
work carrie er

Fig. A

Att station 1 cannot leav ve station 1 after 12 minutes ass station 2 is not freee after 12
miinutes of woork on a prreviously arrrived work carrier. On nly after 16
6 minutes itt is free to
pu
ull work carrrier from station 1. Theerefore, stattion 1 will remain
r idle for (16 – 12
2) = 4 min.
Simmilarly, in each
e cycle, station
s 3,4 and
a 5 would d be idle for 3, 2 and 4 mmin.
Sin
nce, idle tim
me at any sttation is thee un-utilized
d resource, the objectiv
ve of line ba
alancing is
to minimise thhis.

Page 49 of 318
 Line Balancing
S K Mondal Chapter 3
An assembly line consists of (work) stations k = 1, ..., m usually arranged along a conveyor
belt or a similar mechanical material handling equipment. The workpieces (jobs) are
consecutively launched down the line and are moved from station to station. At each
station, certain operations are repeatedly performed regarding the cycle time (maximum or
average time available for each work cycle).
Manufacturing a product on an assembly line requires partitioning the total amount of
work into a set V = {1, ..., n} of elementary operations named tasks. Performing a task j
takes a task time tj and requires certain equipment of machines and/or skills of workers.
The total work load necessary for assembling a workpiece is measured by the sum of task
times tsum. Due to technological and organizational conditions precedence constraints
between the tasks have to be observed.
These elements can be summarized and visualized by a precedence graph. It contains a
node for each task, node weights for the task times, arcs for the direct and paths for the
indirect precedence constraints. Figure 1 shows a precedence graph with n = 9 tasks
having task times between 2 and 9 (time units).
Any type of ALBP consists
in finding a feasible line
balance, i.e., an
assignment of each task
to a station such that the
precedence constraints
(Figure 1) and further
restrictions are fulfilled.
The set Sk of task assigned to a station k (= 1, ..., m) constitutes its station load or work
content, the cumulated task time t(sx ) ¦ js t j is called station time.
k

When a fixed common cycle time c is given (paced line), a line balance is feasible only if the
station time of neither station exceeds c. In case of t(Sk) < c, the station k has an idle time
of c – t(Sk) time units in each cycle. For the example of Figure 1, a feasible line balance
with cycle time c = 11 and m = 5 stations is given by the station loads S1={1, 3}, S2 = {2, 4},
S3 = {5, 6}, S4 = {7, 8}, S5 = {9}.
Because of the long-term effect of balancing decisions, the used objectives have to be
carefully chosen considering the strategic goals of the enterprise. From an economic point
of view cost and profit related objectives should be considered. However, measuring and
predicting the cost of operating a line over months or years and the profits achieved by
selling the products assembled is rather complicated and error-prone. A usual surrogate
objective consists in maximizing the line utilization which is measured by the line
efficiency E as the productive fraction of the line’s total operating time and directly
depends on the cycle time c and the number of stations m. In the most simple case, the line
efficiency is defined as follows: E tsum / (m.c).
™ The classic example is Henry Ford’s auto chassis line.
z Before the “moving assembly line” was introduced in 1913, each chassis was
assembled by one worker and required 12.5 hours.
z Once the new technology was installed, this time was reduced to 93 minutes.
™ Favorable Conditions
z Volume adequate for reasonable equipment utilization.
z Reasonably stable product demand.
z Product standardization.
z Part interchange-ability.
z Continuous supply ofPage
material.
50 of 318
 Line Balancing
S K Mondal Chapter 3
z Not all of the above must be met in every case.
™ Minimum rational work element
z Smallest feasible division of work.
™ Flow time = time to complete all stations
™ Cycle time
z Maximum time spent at any one workstation.
z Largest workstation time.
z How often a product is completed.
z Inverse of the desired hourly output rate = the amount of time available at
each work station to complete all assigned work.

1 2 3 Flow time = 4 + 5 + 4 = 13
Cycle time = max (4, 5, 4) = 5
4 min 5 min 4 min

™ Total work content: Sum of the task times for all the assembly tasks for the
product.
™ Precedence diagram: network showing order of tasks and restrictions on their
performance.
™ Measure of efficiency.
Sum of task times (T )
Efficiency
Actual number of workstations ( N a ) u Cycle time (C )

Constraints in Line Balancing Problem

The operations in any line follow same precedence relation. For example, operation of
super-finishing cannot start unless earlier operations of turning, etc., are over. While
designing the line balancing problem, one has to satisfy the precedence constraint. This
is also referred as technological constraint, which is due to sequencing requirement in the
entire job.
Another constraint in the balancing problem is zoning constraint. If may be either positive
zoning constraint or negative zoning constraint. Positive zoning constraint compels the
designer to accommodate specified work-elements to be grouped together at one station.
For example, in an automobile assembly line, workers are doing work at both sides of
automobile. Therefore, at any station, few operations have to be combined. Many times,
operation and inspection are grouped together due to positive zoning constraint.
In a negative zoning constraint few operations are separated from each other. For example,
any work station, which performs spray painting, may be separate from a station, which
performs welding, due to safety considerations.
Therefore, following constraints must be following in a line balancing problem:
1. Precedence relationship.
2. Zoning constraints (if any).
3. Restriction on number of work stations (n), which should lie between one and total
number of work elements (N). Thus:
1d nd N
4. Station time (Tsi) must lie between cycle time and maximum of all work element time
(Max {TiN}):
Max {TiN} d Tsi d Tc
Page 51 of 318
 Line Balancing
S K Mondal Chapter 3
Definition and Terminology in Assembly Line
1. Work Element (i)
The job is divided into its component tasks so that the work may be spread along the line.
Work element is a part of the total job content in the line. Let N be the maximum number
of work element, which is obtained by dividing the total work element into minimum
rational work element. Minimum rational work element is the smallest practical divisible
task into which a work can be divided. Thus, the work element number (i) is
1d i d N
The time in a work element, i say (TiN), is assumed as constant. Also, all TiN are additive in
nature. This means that we assume that if work elements, 4 and 5, are done at any one
station, the station time would be (T4N + T5N). Where N is total number of work elements?

2. Work Stations (w)

It is a location on the assembly line where a combination of few work elements is
performed. Since minimum number of work stations (w) cannot be less than 1, we have
w¬ t 1

3. Total Work Content (Twc)

This is the algebric sum of time of all the work elements on the line. Thus;
N
Twc ¦T
i 1
iN

4. Station Time (Tsi)

It is the sum of all the work elements (i) on work station (s). Thus, if there are n1 to n2
work elements assigned at station s, then
n2
Tsi ¦T
n1
iN

5. Cycle Time (Tc)

Cycle time is the rate of production. This is the time between two successive assemblies
coming out of a line. Cycle time can be greater than or equal to the maximum of all times,
taken at any station. Necessary clarification is already given in the previous example.
Tc t Max {Tsi}
If, Tc = max {Tsi}, then there will be ideal time at all stations having station time less than
the cycle time.

6. Delay or Idle Time at Station (Tds)

This is the difference between the cycle time of the line and station time.

Tds = Tc – Tsi
7. Precedence Diagram
This is a diagram in which the work elements are shown as per their sequence relations.
Any job cannot be performed unless its predecessor is completed. A graphical
representation, containing arrows from predecessor to successor work element, is shown in
the precedence diagram. Every node in the diagram represents a work element.

8. Balance Delay or Balancing Less

Page 52 (d)
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 Line Balancing
S K Mondal Chapter 3
This is a measure of line-inefficiency. Therefore, the effort is done to minimise the balance
delay. Due to imperfect allocation of work elements along various stations, there is idle
time at station. Therefore, balance delay:
N
nTc  ¦ TiN
nTc  T wc
d i 1
nTc nTc
Where:
Tc = Total cycle time;
Twc = Total work content;
n = Total number of stations.

9. Line Efficiency (LE)

It is expressed as the ratio of the total station time to the cycle time, multiplied by the
number of work stations (n):
n

¦T si
LE i 1
u 100%
 n  Tc 
Where
Tsi = Station time at station i
n = Total number of stations
Tc = Total cycle time

10. Smoothness Index (SI)

Smoothness index is a measure of relative smoothness of a line:

n 2

SI ¦ ª¬ T 
i 1
si max  Tsi º¼
Where,
(Tsi)max = Maximum station time.

Methods of Line Balancing

It is not possible (to date) to have an approach, which may guarantee an optimal solution
for a line balancing problem. Many heuristics exist in literature for this problem. The
heuristic provides satisfactory solution but does not guarantee the optimal one (or the best
solution). We would discuss some of the heuristics on a sample problem of line balancing,
as given below:
Problem: Let us consider the precedence diagram of 13 work elements shown below. The
time for each work element is at the top of each node:
Page 53 of 318
 L
Line Ballancing
S K Mon
ndal Chapter 3

Precedence dia
agram
In a tabular form
m, this preceedence diagrram is repreesented as ffollows:

Work Element Du
uration Immed diate
Elem
ment (min) Precedeence
1 8 –
2 3 1
3 3 1
4 3 1
5 6 2
6 7 4
7 5 3,5,6
6
8 3 7
9 2 7
100 5 7
11 8 8
122 5 10
133 10 12
9,11,1
Total 68

Heu
uristic: Larges
st Cand
didate Rule
R
Step 1: List alll work elem
ments (i) in descending
d order of theeir work elements (TiN) value.
Step 2: Decide e cycle time (Tc).
Step 3: Assignn work elem ment to the station. Sta art from thee top of the list of unasssigned
elemen nts. Select only feasiible elemen nts as per the preced dence and zoning
constraints. Selecct till the sta
ation does not
n exceed cy ycle time.
Step 4: Continnue step 3 foor next station.
Step 5: ments are over, repeat steps 3, 4.
Till alll work elem
Problem 1: Refer the probblem shown in figure beelow. Decidee cycle time
e.
Tottal work con
ntent = 68 m
min.
Largest work element timme = 10 minn.
Th me (Tc) musst satisfy : Tc t 10 min.
hus, cycle tim
68
For minimum
m cy
ycle time of 10 min., nu
umber of sttations wou
uld be 6.8. Therefo
6 ore, we
10
must take statioons lesser than this. LLet us selecct 5 stations design. For
F 5 station ns, the
68
statio
on time shouuld be nearrly equal to 13.6 min. List w work elemeents in desccending
5
order of their worrk element.
Work ellement TiN Imm
mediate Prrecedence
13
3 10 9 11 12

Page 54 of 318
 Line Balancing
S K Mondal Chapter 3
6 7 4
5 6 2
7 5 3,5,6
10 5 7
12 5 10
2 3 1
3 3 1
4 3 1
8 3 7
9 2 7
Step 3:
Station Element TiN 6 TiN at Station
I 1 8
2 3
3 3 14
II 4 3
6 7
5 6 16
III 7 5
10 5
8 3 13
IV 11 8
12 5
9 2 15
V 13 10 10
Here, final cycle time is maximum station time which is 16 min.

nTc  ¦ TiN
Balance delay
¦ nTc
5 u 16  68
u 100% 15%
5 u 16

Let us consider a 4-station design:

¦ TiN
Approximate cycle time
No.of Stations
68
17 min .
4

Station Element TiN 6 TiN at Station

I 1 8
2 3
3 3
4 3 17
II 6 7
Page 55 of 318
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S K Mon
ndal Chapter 3
5 6
7 5 18
III 10 5
8 3
11 8 16
IV 12 5
9 2
13 10 17

Since maximum station tim

me is 18 min. (for statiion II), the cycle time would alsoo be 18
min.
4 u 18  68
Here, Balance delay
d u 100
0% 5.55%.
4 u 18

As th
he balance delay
d is qu
uite less in 4-station design,
d we may select 4-station designs
d
provid
ded the capa
acity of stattion II is at least 18 min
n.

S
Station line
e design fo
or Problem
mI

Physical lay
yout of 4-sttation desiign

Kilb
bridge-W
Westerr Heuris
stic for Line Balancin
ng
Page 56 of 318
 Line B
Balancin
ng
S K Mo
ondal Cha
apter 3
Step 1: Connstruct preecedence diaagram. Mak ke a colummn I, in whhich includee all work
elem
ments, whiich do not have
h a preccedence work elementt. Make colu umn II in
which list all elements,
e n column I. Continue till all work
which follow elements in
elem
ments are exhausted.
e
N
Step 2: Dettermine cyccle time (Tc) by finding
g all combinations of the
t primes of ¦T
i 1
iN

which is the total

t elemen
ntal time. A feasible cy
ycle time iss selected. Number
N of
sta
ations would
d be:
N

¦T iN
n i 1

Tc
Step 3: Asssign the worrk elementss in the work k station soo that total sstation timee is equal
to or
o slightly leess than the
e cycle timee.
Step 4: Reppeat step 4 for unassignned work ellements.

Seven co
olumn inittial assignm
ment

No
ow, selecting
g cycle timee as equal too 18 secondss we follow these
t steps::
Column Work Element,
E TiN Colum
mn Sum Cumula
ative
(i) Sum
m
I 1 8 8 8
II 2 3
3 3
4 3 9 17
III 5 6
6 7 13
1 30
IV 7 5 5 35
V 8 3
9 2
10 5 10
1 45
VI 11 8
12 5 13
1 58
VII 13 10 10
1 68
(tmax)

Tootal elementtal time is 68

6 minutes which
w is 2 × 2 × 17. Th
he cycle timee must lie between 68
(fo
or one statioon) to 10 min
n. (which is max of all TiN):
10 d Tc d 68

Page 57 of 318
 Line Balancing
S K Mondal Chapter 3
The possible combinations of primes (17, 2 and 2) of work content time (68 min) are as
follows:
Feasible Cycle Time Infeasible Cycle Time
17 2
17 × 2 = 34 2×2=4
17 × 2 × 2 = 68

Let us arbitrarily select 17 as the cycle time. Now, regroup elements in columns I and II
till we get 17 min. of station time. Thus, elements 1, 2, 3, 4 are selected at station I. We
proceed in the same way for remaining elements:
Station Element TiN Station Sum (Tc – Tsi) for Tc = 17
(i) (Tsi) min.
I 1 8
2 3
3 3
4 3 17 0
II 5 6
6 7 13 4
III 7 5
8 3
9 2
IV 10 5 15 2
11 8
12 5 13 4
V 13 10 10 7

68
Line Efficiency u 100 80%
5 u 17
Smoothness Index 0 2  4 2  22  4 2  7 2 85 9.22
5 u 17  68
Balance Delay u 100 20%
5 u 17

Now, locking at the previous table, little readjustment in work element is possible if the
cycle time is extended to 18 min. This is apparent when we consider the following
grouping:
Column Work Element TiN Station Sum (Tc - Tsi) for Tc = 18
(i) (Tsi) min.
I 1 8
2 3
3 3
II 4 3 17 1
5 6
6 7
7 5 18 0
III 8 3
9 2
10 5
11 8 18 0
IV 12 5
13 10 15 3

Page 58 of 318
 Line B
Balancin
ng
S K Mo
ondal Cha
apter 3
68
Lin
ne Efficienccy u 100
0 94.44%
4 u 18

Sm
moothness In
ndex 12  3 2 10 3.16

4 u 18  68
Ba
alance Delay
y u 100 5.56
6%
4 u 18

Heuristic
c: He
elgeson
n-Birnie
e (Ranked Posiitional
Weight)
W Method
d
Fo
ollowing steps
s are followed:
f
Step 1: Draaw the precedence diag gram.
Step 2: Forr each workk element, determine
d th
he positionaal weight. It
I is the totaal time on
thee longest path from thee beginning of the operation to thee last operattion of the
nettwork.
Step 3: Ran nk the work elementts in desceending orde er of rankeed position nal weight
(R.P.W.).
Callculation of RPW would
d be explain
ned in the ex
xample to foollow.
Step 4: Asssign the woork element to a station n. Choose the
t highest RPW eleme ent. Then,
seleect the neext one. Coontinue tilll cycle tim me is not v violated. Follow
F the
pre
ecedence connstraints alsso.
Step 5: Reppeat step 4 till all opera
ations are allotted
a to on
ne station.

Ex
xample: Let
L us con
nsider the previous example. The prece
edence diagram is
sh gure above. Assume cycle
hown in fig c time is 18 min.
So
olution:

Reefer figure above

a RPW ofo any work k element (i)) is the sum
m of the timee of work eleements on
thee longest pa ath, starting
g from ith woork elementt to the lastt work element. Therefoore, for all
acttivities, firsst find the loongest path
h, starting ffrom that ellement to th
he last workk element.
Th
his is given in i last colum
mn of table below:
Th
he ranked poositional weeight (RPW)) of all work
k elements, i, is shown below:
b
Work Ele
ement, i Rannk RPWW Longest Path
P
1.. 1 44 1
1–4–6–7–8– –11–13
2.. 3 35 2–5–7–8–111–13
3.. 6 29 3–7–8–111–13
4.. 2 36 4–6–7–8–111–13
5.. 5 32 5–7–8–111–13
6.. 4 33 6–7–8–111–13
7.. 7 26 7–8–11––13
8.. 8 21 8–11–113
9.. 12 12 9–13

Page 59 of 318
 L
Line Ballancing
S K Mon
ndal Chapter 3
12. 11 15 12–13
13. 13 10 13

Assig
gnment of work
w station is done
e as followss:
Sta
ation Element, Element T
Time, Station T
Time, Tc – Tinn
(i) (TiN) (TiN )
I 1 8
4 3
6 7 18 0
II 2 3
3 3
5 6
III 7 5 17 1
8 3
9 2
10 5
11 8 18 0
IV 12 5
13 10 15 3

688
Line Efficiency
E u 100 9
94.44%
18 u 4
Smootthness Indeex 0 2  12  0 2  3 2 3.16
4 u 18  68
Balan
nce Delay u 100 5.56%
4 u 18

Problem: Design n the work stations forr an assemb

bly line shown below. Use
U RPW method.
m
Desireed cycle tim
me is 10 min
nutes.

Soluttion:
N
Twc ¦T
i 1
iN
= Tootal work coontent = 2 + 4 + 1 + 2 + 2 + 3 + 3 + 2 + 1 + 5 + 3 + 2 + 1 + 3 = 34

Rang
ge of cycle time:
N
Max (TiN ) d Tc d ¦T
i 1
iN o 5 d Tc d 34
or 4

Desireed cycle tim

me C = 10 miin.

Page 60 of 318
 Line B
Balancin
ng
S K Mo
ondal Cha
apter 3
¦ TiN 34
Miinimum nu
umber of work
w statio
ons 4 4
3.4
Tc 10

Us
sing Rank Position Weight
W (RP
PW) method
d:
Tassk RPWW
1 (20)
3 (18)
2 (17)
4 (14)
5 (13)
9 (11)
6 (12)
7 (11)
10
0 (8)
8 (7)
11
1 (6)
12
2 (5)
14
4 (5)
13
3 (3)

No
ow, groupiing on the basis of we
eight:

ª N
º
« ¦ TiN »
T
Total Ideal Time
(a)) Balance Delay
D «1  i 1 »
« nTc » Time u No. of Stations
Cycle T
«¬ ¼»

ª 34 º
«1  4 *10 » *1
100 15%
¬ ¼

(b) Line Efficien

E ncy = [1 – Balan
nce dela
ay] * 10
00
= [1 – 0.15] * 100
= 85%%

n 2

(c)) Smoothness Index ¦ ª¬(Ts )max

i 1
m  Tsi º¼

10  10  10  9  10  10  10  5
2 2 2 2
0  1  0  25 26 5.1

Selective
e Assembly
Se
elective asssembly in manufacturring is a tecchnique of assembly
a in
n which parrts are not

Page 61 of 318
 Line Balancing
S K Mondal Chapter 3
assembled with any of the parts in the corresponding category of the mating component.
This allows for greater variability in the production of the individual components, but this
benefit is at least partially negated by the introduction of part sorting.

Selective assembly is a method of obtaining high-precision assemblies from relatively low-

precision components. In selective assembly, the mating parts are manufactured with wide
tolerances. The mating part population is partitioned to form selective groups, and
corresponding selective groups are then assembled interchangeably. If the mating parts
are manufactured in different processes and in different machines, their standard
deviations will be different. It is impossible that the number of parts in the selective group
will be the same. A large number of surplus parts are expected according to the difference
in the standard deviations of the mating parts. A method is proposed to find the selective
groups to minimize the assembly variation and surplus parts when the parts are
assembled linearly. A genetic algorithm is used to find the best combination of the
selective groups to minimize the assembly variation. Selective assembly is successfully
applied using a genetic algorithm to achieve high-precision assemblies without sacrificing
the benefit of wider tolerance in manufacturing.

Capacity Planning
Capacity planning
Capacity planning forms the second principal step in the production system, the Product
and Service design step being the first. The term “Capacity” of a plant is used to denote the
maximum rate of production that the plant can achieve under given set of assumed
operating conditions, for instance, number of shifts and number of plant operating days
etc.
Capacity planning is concerned with determining labour and equipment capacity
requirements to meet the current master production schedule and long term future needs
of the plant.
Short term capacity planning involves decisions on the following factors:
(a) Employment levels
(b) Number of work shifts
(c) Labour overtime hours
(d) Inventory stock piling
(e) Order back logs
(f) Subcontracting jobs to other plants/shops in busy periods.
Long term capacity planning involves decisions on the following factors
(i) Investment in new machines/equipments
(ii) New plant construction
(iii) Purchase of existing plants
(iv) Closing down/selling obsolete facilities.

Page 62 of 318
 Line B
Balancin
ng
S K Mo
ondal Cha
apter 3

OBJEC
CTIVE QUES S (GA
STIONS ATE, IES,
I IA
AS)

P
Previou
us 20-Y
Years GATE
E Questions
GA
ATE-1. The table given deta
ails of an a
assembly liine. [GA
ATE-2006]

he line efficiency of tthe assemb

What is th bly line?
(a) 70% ( 75%
(b) (c)) 80% (d) 85%

GA
ATE-2. In an assembly linee for assem mbling toyys, five workers are assigned
tasks which take tim
mes of 10, 8, 6, 9 and 10 minutees respectivvely. The
balance delay
d for th
he line is: [GAATE-1996]
(a) 43.5% ( 14.8%
(b) (c)) 14.0% (d) 16.3%

GA
ATE-3. An electr ronic equ uipment m manufactur rer has d decided to o add a
componen nt sub-ass sembly op peration that
t can produce 80 units
during a regular 8-hour sh hift. This operation consists of three
activities as below: [GAATE-2004]
Activitty Standard time (miin.)
M. Mechan nical assembbly 1
12
E. Electricc wiring 1
16
T. Test 0
03
For line balancing
b the numb ber of wor rk station ns required d for the
activities M, E and T would re espectivelyy be
(a) 2, 3, 1 ( 3, 2, 1
(b) (c)) 2, 4, 2 (d) 2, 1, 3

GA
ATE-4. The produ
uct structu
ure of an assembly
a P is shown iin the figu
ure.

Estimated
d demand for
f end pro
oduct P is as followss: [GA
ATE-2008]
Week 1 2 3 4 5 6
Demand 1000 1000 1000 1000 1200 1200
Ignore leead times for asse embly and d sub-asse embly. Pr roduction
capacity (per week k) for compponent R is the botttleneck op peration.
Starting with
w zero inventory,
i , the smalllest capaciity that wiill ensure
a feasible productio
on plan up to week 6 is:
(a) 1000 ( 1200
(b) (c)) 2200 (d) 2400

Previo
ous 20
0-Years
s IES Questi
Q ions
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Reason (R): Assembly line balancing reduces in-process inventory.
(a) Both A and R are true and R is the correct explanation of A
(b) Both A and R are true but R is NOT the correct explanation of A
(c) A is true but R is false [IES-2009]
(d) A is false but R is true

IES-2. Consider the following characteristics of assembly line balancing:

1. shareout of sequential work activities into work stations
2. High utilization of equipment
3. Minimization of idle time
Which of the statements given above are correct? [IES-2008]
(a) 1, 2 and 3 (b) 1 and 2 only
(c) 2 and 3 only (d) 1 and 3 only

IES-3. Which of the following are the benefits of assembly line balancing?
1. It minimises the in-process inventory [IES-1998]
2. It reduces the work content.
3. It smoothens the production flow
4. It maintains the required rate of output.
Select the correct answer using the codes given below:
Codes: (a) 1, 2 and 3 (b) 2, 3 and 4 (c) 1, 3 and 4 (d) 1, 2 and 4

IES-4. In an assembly line, what is the balance delay? [IES 2007]

(a) Line efficiency × 100 (b) 100 – Line efficiency (in percentage)
Line efficiency
(c) (d) None of the above
100

IES-5. In an assembly line, when the workstation times are unequal, the
overall production rate of an assembly line is determined by the:
(a) Fastest station time [IES-2006]
(b) Slowest station time
(c) Average of all station times
(d) Average of slowest and fastest station times

IES-6. Which one of the following is true in respect of production control

for continuous or assembly line production? [IES-2002]
(a) Control is achieved by PERT network
(b) Johnson algorithm is used for sequencing
(c) Control is on one work centre only
(d) Control is on flow of identical components through several operations

IES-7. Manufacturing a product requires processing on four machines A,

B, C, D in the order A – B – C – D. The capacities of four machines
are A = 100, B = 110, C = 120 and D = 130 units per shift. If the
expected output is 90% of the system capacity, then what is the
expected output? [IES-2006]
(a) 90 units (b) 99 units (c) 108 units (d) 117 units
IES-8. Match List-l (Parameter) with List-II (Definition) and select the
correct answer using the code given below the lists: [IES-2006]
List-I List-II
A. Total work content 1. Aggregate of all the work elements to be
done on line
B. Workstation process time 2. Line inefficiency which results from the
idle time due to imperfect allocation of
work among stations
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C. Cycle time 3. Time interval between parts coming off
the line
D. Balance delay 4. Sum of the times of the work elements
done at a station
Codes: A B C D A B C D
(a) 1 4 3 2 (b) 1 2 3 4
(c) 3 4 1 2 (d) 3 2 1 4

IES-9. A production line is said to be balanced when [IES-1997]

(a) There are equal number of machines at each work station
(b) There are equal number of operators at each work station
(c) The waiting time for service at each station is the same
(d) The operation time at each station is the same.

IES-10. A production system has a product type of layout in which there are
four machines laid in series. Each machine does a separate
operation. Every product needs all the four operations to be carried
out. The designed capacity of each of the four machines is 200, 175,
160 and 210 products per day. The system capacity would be:
(a) 210 products per day (b) 200 products per day [IES-2000]
(c) 175 products per day (d) 160 products per day

IES-11. A new facility has to be designed to do all the welding for 3

products: A, B and C, Per unit welding time for each product is 20 s,
40 s and 50 s respectively. Daily demand forecast for product A is
450, for B is 360 and for C is 240. A welding line can operate
efficiently for 220 minutes a day. Number of welding lines required
is: [IES-2001]
(a) 5 (b) 4 (c) 3 (d) 2

IES-12. A company has four work centres A, B, C and D, with per day
capacities of 450 units, 390 units, 360 units and 400 units
respectively. The machines are laid down in order A, B, C, and D
and product has to be operated on all these machines for getting
converted into finished product. The actual output turns to be 306
units per day. What is the system efficiency? [IES-2004]
(a) 68% (b) 78% (c) 80% (d) 85%
IES-13. An operations consultant for an automatic car wash wishes to plan
for enough capacity of stalls to handle 60 cars per hour. Each car
will have a wash time of 3 minutes, but there is to be a 20%
allowance for set-up time, delays and payment transactions. How
many car wash stalls should be installed? [IES-1999; 2003]
(a) 3 (b) 4 (c) 5 (d) 6

IES-14. An operations consultant for an automatic car wash wishes to plan

for enough capacity to handle 60 cars per hour. Each car will have a
wash time of 4 minutes, but there is to be a 25% allowance for setup
time, delays and payment transactions. How many car wash stalls
should be installed? [IES-2009]
(a) 3 (b) 4 (c) 5 (d) 6
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 L
Line Ballancing
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ndal Chapter 3

IES-1
15. Co
onsider the
e following
g sets of ta
asks to com
mplete the
e assembly
y of an
en
ngineering componen nt: [IES
S-1997]
Ta
ask Time (iin seconds)) Preceden
nce
Task
k Time (iin seconds)) Precedenc
ce
A 10 –
B 20 –
C 15 A
D 5 B
E 30 C
F 15 E
G 5 D
Thhe expecteed production rate is 3000 u units per shift of 8 hour
duuration. Th
he minimaal number of worksttations tha
at are need ded to
achieve this productio
on level is:
(a) 4 (b) 8 (c) 10
0 (d) 11

IES-1
16. A product is manufa actured byb
processing on the four f work
k-
sta
ation (WS S). The c capacity ofo
each machiine on th hese work k-
sta
ations is given
g in thhe diagramm
as shown ab bove. In th he diagramm
M11, M2A, M22B, M3, M4 4A and M4B B
aree the mac chines and 500, 275 5,
275, 560, 200 and 200 0 are theiir
capacities in
n number o of productts
maade per sh hift. If thhe productts
maade in thiss system are 5%, then
whhat will be
e the outpu ut from thiis [IES
S-2009]
sysstem?
(a) 380 (b) 4
475 (c) 52
22 (d) 532
2

Ca
apacitty Pla
annin
ng
IES-1
17. Maatch List-II (PPC fun nctions) with
w List-III (Activity)) and sele ect the
correct answwer using tthe codes given
g below w the lists:: [IES
S-2004]
List-I L
List-II
A. Capacity planning
p 1. Listing
L prod ducts to be assembleed and
w
when to be ddelivered
B. Shop floor control 2. Reschedulin
R ng orders ba ased on prodduction
p
priorities
C. Master produuction 3. Closure
C tolerrances
schedule
D. Material requireement 4. Monitor
M proogress of orders
o and report
planning th
heir status
5. Planning
P of labour and equipment
Co
odes: A B C D A B C D
(a) 1 4 3 2 (b) 5 2 1 4
(c) 1 2 3 4 (d) 5 4 1 2

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 Line Balancing
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1. Capacity planning [IES-2008]
2. Material requirement planning
3. Purchasing
4. Design decisions
Which one of the following is the correct sequence of the above
steps in operations management?
(a) 2 – 3 – 4 – 1 (b) 2 – 4 – 3 – 1
(c) 4 – 1 – 2 – 3 (d) 1 – 2 – 4 – 3

Previous 20-Years IAS Questions

IAS-1. A work shift is for 8 hours duration; 30 minutes lunch break and two
15 minutes (each) tea breaks are allowed per shift. If products are to
go out after assembly at the rate of 60 per shift, and total assembly
time content for a product is 42 minutes, then minimum number of
work stations needed is: [IAS-2002]
(a) 8 (b) 12 (c) 6 (d) 5

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S K Mondal Chapter 3

Answers with Explanation (Objective)

Previous 20-Years GATE Answers

Total time used
GATE-1. Ans. (c) Line efficiency u 100
Number of work stations × Cycle time
48
u 100 80%
6 u 10
GATE-2. Ans. (c) Balance delay = 100 – Line efficiency (in percentage).
GATE-3. Ans. (a)
GATE-4. Ans. (c)

Previous 20-Years IES Answers

IES-1. Ans. (b)
IES-2. Ans. (a) All the three statements are correct with respect to assembly line
balancing:
1. Apportionment of sequential work activities into work stations
2. High utilization of equipment
3. Minimization of idle time
IES-3. Ans. (c)
IES-4. Ans. (b)
IES-5. Ans. (b)
IES-6. Ans. (b)
IES-7. Ans. (a) In the sequence of A – B – C – D only minimum output have to be
calculated. Other machines will be on empty position.
? Output K u 100 0.9 u 100 90 units
IES-8. Ans. (a)
IES-9. Ans. (d)
IES-10. Ans. (d)
450 u 20  360 u 40  240 u 50
IES-11. Ans. (c) N 2.68 above whole number is 3.
220 u 60
IES-12. Ans. (d) Maximum possible output 360 units per day
Actual output is 306 per day
306
? K u 100% 85%
360
60
IES-13. Ans. (b) One stall can wash | 16 car/hr
3 u 1.20
No. of wash stall = 4
IES-14. Ans. (d) Wash time for each car = 4 u 1.25 = 5 min.
60
Number of cars washed in one hour in one stall = 12
5
60
Number of car wash stalls to be installed = 5
12
IES-15. Ans. (d) Precedence is such that there is no waiting time. Total time for one
assembly is 100 sec. Page 68 of 318
 Line Balancing
S K Mondal Chapter 3
3000 u 100
? No. of stations  11
8 u 60 u 60
IES-16. Ans. (a) Given that products made in the system are 5% defective. Therefore
percentage of items without any defects = 100 – 5 = 95.
Among all the four station WS4 station has minimum number of raw
material = 400
? Output from this system = (200 + 200) × 0.95 = 380
IES-17. Ans. (b) PPC: Production planning and control.
IES-18. Ans. (c) Design decision o Capacity planning o Material requirement planning
o Purchasing.

Previous 20-Years IAS Answers

IAS-1. Ans. (c) Effective work 7 hr/shift. Effective work hour needed to produce 60 per
shift = 42 hr/shift.
? Work station needed = 42/7 = 6.

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 Line Balancing
S K Mondal Chapter 3

Conventional Questions with Answer

Assembly Line Balancing

Conventional Question [CSE-1990]
The following elemental data pertains to the assembly of a new model toy:
Element No. Elemental Time (Min) Immediate Predecessors
1 0.5 —
2 0.3 1
3 0.8 1
4 0.2 2
5 0.1 2
6 0.6 3
7 0.4 4, 5
8 0.5 3, 5
9 0.3 7, 8
10 0.6 6, 9

The desired value of the cycle times 1.0 min, compute.

(i) The balance delay and
(ii) The theoretically minimum number of stations required so as to minimize the
balance delay. Also mention some of the steps you would recommended to improve
the line balance.
Solution:
F
4

C 7
2 5
1 E G 9 10
A B H I
3 8 6

4.3
(i) E= 43%; Therefore Delay 100  43 57%
10 u 1

Conventional Question [ESE-2007]

An Assembly of an equipment involves the tasks A to N, the precedence tasks and
processing times of these tasks in minutes are given in the following table.
Considering cycle time of 20 minutes at any work station, balance the assembly line
and find the optimum number of work stations. Also find the idle time at each work
station.
Task Predecessor Duration
A - 6
B - 5
C - 4
D A 8
E B 5
F C 4
G D 7
H E 6
I F
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 Line Balancing
S K Mondal Chapter 3
J G 10
K I 7
L J, H 10
M K 6
N L, M 9 [10-Marks]
Solution:
8 7 10
6 A D G J

5 6 10 9
5 B E H L N

4 10 7
4 C F I K M
6
Precedence diagram
The table below shows some possibilities of grouping the tasks in to work stations.
Balancing the work station has been shown in the below table.
The optimum number of work station is 6.
Work Grouping Work Grouping Work Grouping Work Idle
station (First) station (Second) station (Third) station time in
number time in time in time in minutes
minutes minutes minutes
1 A, B, C 15 A, D, B 19 A, B, D 19 1
2 D, E, F 17 C, F, I 18 C, E, F 13 7
3 G, J 17 G, H, E 18 G, K 17 3
4 H, L 16 J, L 20 H, L 16 4
5 I, K 17 K, M 13 I, K 17 3
6 M, N 15 N 9 M, N 15 5

97 97 97

Also the idle time has been shown in the below the table against grouping no 3.
Also the balance delay
Total idle time for the
assembly line
=
Total time taken by a product
from the first work station to
the last work station

=

100 nC  ¦ t i 
nC
Where, n = total number of work stations
C = cycle time
ti = time for the ith elemental task
100  6 u 20  97 
6 u 20
= 19.2%

Page 71 of 318