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Factory Layout - Basics

The document discusses methods for designing factory layouts and balancing assembly lines. It defines key terms like precedence requirements, workstations, cycle time, line balancing, and efficiency. Precedence diagrams and positional weight techniques are presented as ways to model precedence relationships and assign work elements to balanced workstations. The goal is to maximize efficiency while meeting precedence and cycle time constraints. Computerized methods use heuristics to balance large assembly lines at an acceptable efficiency.

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Harsh Dixit
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
16 views

Factory Layout - Basics

The document discusses methods for designing factory layouts and balancing assembly lines. It defines key terms like precedence requirements, workstations, cycle time, line balancing, and efficiency. Precedence diagrams and positional weight techniques are presented as ways to model precedence relationships and assign work elements to balanced workstations. The goal is to maximize efficiency while meeting precedence and cycle time constraints. Computerized methods use heuristics to balance large assembly lines at an acceptable efficiency.

Uploaded by

Harsh Dixit
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 12

Creating Factory Layout

Dr. Deepu Philip

1 10/19/2023
Designing Product Layouts
 Goal is to balance the assembly line

 Precedence requirements are physical restrictions in the


order in which operations are performed
 Specify which operations must precede others, which can be
done concurrently, and which must wait until later

 Another objective is to attain the required output rate as


efficiently as possible
 For this, first, each job is to be broken down into the smallest
indivisible proportions called as work elements
 The work elements are then grouped to work stations so that
product flow is smooth through the assembly line

2 10/19/2023
Workstation
 Is any area along the assembly line that requires at least
one worker or one machine

 If each work station on the assembly line takes the same


amount of time to perform the work elements that are
assigned
 Then products will move successively from workstation to
workstation without waiting
 Also no need for worker to be idle

 This process of equalizing the amount of work at each


workstation is called line balancing

3 10/19/2023
Line Balancing
 Assembly line balancing has two constraints
 Precedence
 Cycle time

 Precedence requirements are usually expressed as


precedence diagram
 Precedence diagram is a network that describes any
restrictions on the order in which work elements must be
performed
 Work elements represented by nodes and precedence
relationships represented by directed line segments (arcs)

4 10/19/2023
Example 1

5 10/19/2023
Cycle Time
 It is the maximum amount of time a product is allowed to
spend at each workstation
 Mathematically: max{ individual time at workstations}

 Calculated by dividing the time available for production by


the number of units to be produced

 Cycle time can also be viewed as the time between


completed items rolling off the assembly line

 Time required to complete an item is known as flow time


or lead time
6 10/19/2023
Line Efficiency
 For small layout problems, method of trial and error will
work, but not for large problems some guideline is a must

 Line efficiency along with theoretical minimum number of


workstations can be used as a guideline to create
workstations j

∑t
j

∑t i
i

Efficiency = i =1 # WS = i =1

nC C
 Where ti is the completion time of element i, j is the
number of work elements, n is the actual number of work
stations, and C is the cycle time
7 10/19/2023
Example 2

8 10/19/2023
Balance Delay
 Total idle time of the line is called as balance delay

 Balance delay is calculated as (1 – efficiency) in


percentage

 Actual cycle time is the maximum workstation time on


the line

 Actual efficiency is obtained by dividing with the actual


cycle time
 It is very difficult to attain 100% efficiency or theoretical
number of workstations

9 10/19/2023
Computerized Line Balancing
 COMSOAL – Computer Method for Sequencing
Operations for Assembly Line by IBM
 ASYBL – Assembly Line Configuration Program by GE
 Both can assign hundreds of work elements to
workstations on assembly line

 They do not guarantee optimal solutions, instead they use


various heuristics to balance line at an acceptable
efficiency

 Most common is ranked positional weight technique


10 10/19/2023
Ranked Positional Weight Technique
 Compute the cycle time.
 Construct the precedence network.
 Compute the positional weight for each element, which is the
element’s operation time plus the operation time of all
elements following that element in the network.
 Sort the positional weights in the descending order and create
the ranking.
 Start assigning elements to workstations in the rank order.
Keep on adding elements to the workstation until time on
workstation is less than or equal to the cycle time.
 If no more elements can be added, create the workstation
 Repeat until all elements are assigned.
11 10/19/2023
Example 3

12 10/19/2023

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