D D
D D
G G
G G
G G
M M
M M
M M
A A
A A
L
L L
L L
L L
L
LayoutLayout
What Is Layout What Is Layout Planning?Planning?
• What centres should the layout include?
• How much space and capacity does each centre need?
• How should each centre’s space be
configured?
• Where should each centre be located?
Strategic IssuesStrategic Issues
• Facilitating the flow of materials
• Increasing the efficient utilization of labour and equipment
• Increasing customer convenience
• Reducing hazards to workers
• Improving employee morale
• Improving communication
Criteria for a Good Criteria for a Good LayoutLayout• Maximum flexibility• Maximum co-ordination• Maximum use of volume• Maximum visibility• Maximum accessibility
Criteria for a Good Criteria for a Good LayoutLayout• Minimum distance• Minimum handling• Minimum discomfort• Inherent safety• Maximum security• Efficient material flow• Identification
Layout TypesLayout Types
• Process Layout
• Product Layout
• Fixed-Position Layout
• Hybrid Layout - Cells
Layout Types - Process Layout Types - Process LayoutLayout
Layout Types - Process Layout Types - Process LayoutLayout
Organizes resources around the process and groups work stations or departments according to function
Intermittent, low volume, high-variety
Layout Types - Process Layout Types - Process LayoutLayout
FoundryMilling
machines
LathesGrinding
Painting Drills
Office
Welding
Forging
(a) Layout of a job shop
Layout Types - Process Layout Types - Process LayoutLayout
(a) Layout of a job shop
FoundryMilling
machines
LathesGrinding
Painting Drills
Office
Welding
Forging
Layout Types - Process Layout Types - Process LayoutLayout
(a) Layout of a job shop
FoundryMilling
machines
LathesGrinding
Painting Drills
Office
Welding
Forging
Layout Types - Process Layout Types - Process LayoutLayout
(a) Layout of a job shop
FoundryMilling
machines
LathesGrinding
Painting Drills
Office
Welding
Forging
Layout Types - Process Layout Types - Process LayoutLayout
FoundryMilling
machines
LathesGrinding
Painting Drills
Office
Welding
Forging
(a) Layout of a job shop
Layout Types - Process Layout Types - Process LayoutLayout
Advantages
General purpose, flexible resources are less capital intensive
Less vulnerable to changes in product mix or new market strategies
Equipment utilization can be higher, because not dedicated to one product line
Employee supervision can be more specialized
Layout Types - Process Layout Types - Process LayoutLayout
Disadvantages
– Slower processing rates
– Lost production time during setups
– More capital and more floor space tied up with inventory
– Longer manufacturing lead times
– Costly materials handling, requiring variable path devices
– Production planning and control more difficult
Layout Types - Process Layout Types - Process LayoutLayout
A major challenge in designing process layouts is to identify dominant flow patterns among the jumbled traffic and to locate centres so that materials handling is minimized.
Layout Types - Product Layout Types - Product LayoutLayout
Layout Types - Product Layout Types - Product LayoutLayout
Dedicates resources to a product or closely related product family
Repetitive, high-volume, continuous production
Workstations or departments are arranged in a linear path, which is consistent with the routing sequence of the product.
Layout Types - Product Layout Types - Product LayoutLayout
(b) Layout of a production line
Station 1 Station 2 Station 3 Station 4
Layout Types - Product Layout Types - Product LayoutLayout
(b) Layout of a production line
Station 1 Station 2 Station 3 Station 4
Layout Types - Product Layout Types - Product LayoutLayout
(b) Layout of a production line
Station 1 Station 2 Station 3 Station 4
Layout Types - Product Layout Types - Product LayoutLayout
Station 1 Station 2 Station 3 Station 4
(b) Layout of a production line
Layout Types - Product Layout Types - Product LayoutLayout
Advantages
Faster processing rates
Lower inventories
Infrequent setups
Layout Types - Product Layout Types - Product LayoutLayout
Disadvantages
– More risk of layout redesign
– Less flexible
– For low volume, dedicated resources have low utilization
Layout Types - Product Layout Types - Product LayoutLayout
Challenge in designing product layouts
– Minimize resources used to achieve desired output rate
– Balance tasks, equalize the workload assigned to resources
Layout Types - Layout Types - Fixed-position LayoutFixed-position Layout
Layout Types - Layout Types - Fixed-position LayoutFixed-position Layout
Product is fixed in place. Resources come to the product, minimizing number of times product must be moved.
Used for:
Very large products, ships, roads, power plants, airplanes
Service of fragile or bulky items
Layout Types - Layout Types - Fixed-position LayoutFixed-position Layout
Product
Process Process
ProcessProcess
Process
Layout Types - Layout Types - Fixed-position LayoutFixed-position Layout
• Advantages
– Material movement is reduced to a minimum.
– The task is usually carried out by a gang of operators, hence continuity of operators and responsibility is required.
– Production centres often operate independently of each other, and effective scheduling can be planned to ensure minimum total production time.
Layout Types - Layout Types - Fixed-position LayoutFixed-position Layout
• Limitations
– Movement of machines and equipment to the production centre may be costly and time consuming.
– Positioning of the material or object or machines may be cumbersome and costly.
– Machine and equipment utilisation is usually low, owing to handling and positioning time.
– High grades of skill are required.
Muther’s P-Q ChartMuther’s P-Q Chart
Group Group TechnologyTechnology
Group Group TechnologyTechnology
Machine 1
Machine 2
Machine 3
Machine 4Machine
5
Materials in
Finished goods out
One Worker, Multiple MachinesOne Worker, Multiple Machines
Group Group TechnologyTechnology
Group Group TechnologyTechnology
Parts FamiliesParts Families
Source: Mikell P. Groover. Automation, Production Systems, and Computer-Aided Manufacturing. Englewood Cliffs, NJ: Prentice-Hall, 1980, p. 540. Used by permission.
Group Group TechnologyTechnology
Group Group TechnologyTechnology
Drilling
D D
D D
Grinding
G G
G G
G G
Milling
M M
M M
M M
Assembly
A A
A A
Lathing
Receiving and shipping
L
L L
L L
L L
L
Group Group TechnologyTechnology
(a) Jumbled flows in a job shop without GT cells
Drilling
D D
D D
Grinding
G G
G G
G G
Milling
M M
M M
M M
Assembly
A A
A A
Lathing
Receiving and shipping
L
L L
L L
L L
L
Group Group TechnologyTechnology
(a) Jumbled flows in a job shop without GT cells
Drilling
D D
D D
Grinding
G G
G G
G G
Milling
M M
M M
M M
Assembly
A A
A A
Lathing
Receiving and shipping
L
L L
L L
L L
L
Group Group TechnologyTechnology
(a) Jumbled flows in a job shop without GT cells
Drilling
D D
D D
Grinding
G G
G G
G G
Milling
M M
M M
M M
Assembly
A A
A A
Lathing
Receiving and shipping
L
L L
L L
L L
L
Group Group TechnologyTechnology
(b) Line flows in a job shop with three GT cells
Cell 3
L M G G
Cell 1 Cell 2
Assembly area
A A
L M DL
L MShipping
D
Receiving
G
Group Group TechnologyTechnology
(b) Line flows in a job shop with three GT cells
Cell 3
L M G G
Cell 1 Cell 2
Assembly area
A A
L M DL
L MShipping
D
Receiving
G
Group Group TechnologyTechnology
(b) Line flows in a job shop with three GT cells
Cell 3
L M G G
Cell 1 Cell 2
Assembly area
A A
L M DL
L MShipping
D
Receiving
G
Group Group TechnologyTechnology
(b) Line flows in a job shop with three GT cells
Cell 3
L M G G
Cell 1 Cell 2
Assembly area
A A
L M DL
L MShipping
D
Receiving
G
Longhorn Longhorn MachineMachine
60'
90'
Longhorn Longhorn MachineMachine Department Area Needed(ft2)
1 Burr and grind 10002 NC equipment 9503 Shipping and receiving 7504 Lathes and drills 12005 Tool crib 8006 Inspection 700
Total 5400
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine Department Area Needed(ft2)
1 Burr and grind 10002 NC equipment 9503 Shipping and receiving 7504 Lathes and drills 12005 Tool crib 8006 Inspection 700
Total 5400
Figure 10.6
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
Trips Between Departments
Department 1 2 3 4 5 6
1 Burr and grind —
2 NC equipment —
3 Shipping and receiving —
4 Lathes and drills —
5 Tool crib —
6 Inspection —
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
Trips Between Departments
Department 1 2 3 4 5 6
1 Burr and grind — 20 20 80
2 NC equipment — 10 75
3 Shipping and receiving — 15 90
4 Lathes and drills — 70
5 Tool crib —
6 Inspection —
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine Closeness Rating Between Departments
Department 1 2 3 4 5 6
1 Burr and grind —
2 NC equipment —
3 Shipping and receiving —
4 Lathes and drills —
5 Tool crib —
6 Inspection —
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine Closeness Rating Between Departments
Department 1 2 3 4 5 6
1 Burr and grind —
2 NC equipment —
3 Shipping and receiving —
4 Lathes and drills —
5 Tool crib —
6 Inspection —
Closeness Rating
Rating Definition
A Absolutely necessaryE Especially importantI ImportantO Ordinary closenessU UnimportantX Undesirable
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine Closeness Rating Between Departments
Department 1 2 3 4 5 6
1 Burr and grind — E U I U A
2 NC equipment — O U E I
3 Shipping and receiving — O U A
4 Lathes and drills — E X
5 Tool crib — U
6 Inspection —
Closeness Rating
Rating Definition
A Absolutely necessaryE Especially importantI ImportantO Ordinary closenessU UnimportantX Undesirable
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine Closeness Rating Between Departments
Department 1 2 3 4 5 6
1 Burr and grind — E U I U A
2 NC equipment — O U E I
3 Shipping and receiving — O U A
4 Lathes and drills — E X
5 Tool crib — U
6 Inspection —
Explanation Codes
Code Meaning
1 Materials handling2 Shared personnel3 Ease of supervision4 Space utilization5 Noise6 Employee attitudes
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine Closeness Rating Between Departments
Department 1 2 3 4 5 6
1 Burr and grind — E U I U A(3, 1) (2, 1) (1)
2 NC equipment — O U E I(1) (1) (6)
3 Shipping and receiving — O U A(1) (1)
4 Lathes and drills — E X(1) (5)
5 Tool crib — U
6 Inspection —
Explanation Codes
Code Meaning
1 Materials handling2 Shared personnel3 Ease of supervision4 Space utilization5 Noise6 Employee attitudes
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
60'
90'
2 4 3
6 5 1
Departments 3 and 6 close together Departments 1 and 6 close together Departments 2 and 5 close together Departments 4 and 5 close together
Figure 10.6
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
60'
90'
4 3
Departments 3 and 6 close together Departments 1 and 6 close together Departments 2 and 5 close together Departments 4 and 5 close together
Example 10.1
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
60'
90'
4 3
Departments 3 and 6 close together Departments 1 and 6 close together Departments 2 and 5 close together Departments 4 and 5 close together
6
Example 10.1
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
60'
90'
4 3
Departments 3 and 6 close together Departments 1 and 6 close together Departments 2 and 5 close together Departments 4 and 5 close together
61
Example 10.1
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
60'
90'
4 3
Departments 3 and 6 close together Departments 1 and 6 close together Departments 2 and 5 close together Departments 4 and 5 close together
61
5
2
Example 10.1
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
60'
90'
4 3
Departments 3 and 6 close together Departments 1 and 6 close together Departments 2 and 5 close together Departments 4 and 5 close together
61
5
2
Figure 10.7
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
Trips Between Departments
Department 1 2 3 4 5 6
1 Burr and grind — 20 20 80
2 NC equipment — 10 75
3 Shipping and receiving — 15 90
4 Lathes and drills — 70
5 Tool crib —
6 Inspection —
Example 10.2
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
Load Distance Analysis
Current Plan Proposed Plan
Dept Closeness Distance DistancePair Factor, l d ld Score d ld Score
1,2 201,4 201,6 802,3 102,5 753,4 153,6 904,5 70
Example 10.2
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
Load Distance Analysis
Current Plan Proposed Plan
Dept Closeness Distance DistancePair Factor, l d ld Score d ld Score
1,2 20 31,4 20 21,6 80 22,3 10 22,5 75 23,4 15 13,6 90 34,5 70 1
Example 10.2
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
Load Distance Analysis
Current Plan Proposed Plan
Dept Closeness Distance DistancePair Factor, l d ld Score d ld Score
1,2 20 3 601,4 20 2 401,6 80 2 1602,3 10 2 202,5 75 2 1503,4 15 1 153,6 90 3 2704,5 70 1 70
ld =785
Example 10.2
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
Load Distance Analysis
Current Plan Proposed Plan
Dept Closeness Distance DistancePair Factor, l d ld Score d ld Score
1,2 20 3 60 1 201,4 20 2 40 1 201,6 80 2 160 1 802,3 10 2 20 3 302,5 75 2 150 1 753,4 15 1 15 1 153,6 90 3 270 1 904,5 70 1 70 1 70
ld =785 ld = 400
Example 10.2
60'
90'
2 4 3
6 5 1
Longhorn Longhorn MachineMachine
Load Distance Analysis
Current Plan Proposed Plan
Dept Closeness Distance DistancePair Factor, l d ld Score d ld Score
1,2 20 3 60 1 201,4 20 2 40 1 201,6 80 2 160 1 802,3 10 2 20 3 302,5 75 2 150 1 753,4 15 1 15 1 153,6 90 3 270 1 904,5 70 1 70 1 70
ld =785 ld = 400
Example 10.2
A-1 Distribution A-1 Distribution SystemsSystems
A-1 Distribution A-1 Distribution SystemsSystems
Figure 10.8
Dock Aisle
Storage area
Storage area
A-1 Distribution A-1 Distribution SystemsSystems
Trips to and Area NeededDepartment from Dock (blocks)
1. Toasters 280 12. Air conditioners 160 23. Microwaves 360 14. Stereos 375 35. TVs 800 46. Radios 150 17. Bulk storage 100 2
Example 10.3
Dock Aisle
Storage area
Storage area
A-1 Distribution A-1 Distribution SystemsSystems
Trips to and Area NeededDepartment from Dock (blocks) Ratio Rank
1. Toasters 280 1 280/1 = 2802. Air conditioners 160 2 160/2 = 803. Microwaves 360 1 360/1 = 3604. Stereos 375 3 375/3 = 1255. TVs 800 4 800/4 = 2006. Radios 150 1 150/1 = 1507. Bulk storage 100 2 100/2 = 50
Example 10.3
Dock Aisle
Storage area
Storage area
A-1 Distribution A-1 Distribution SystemsSystems
Trips to and Area NeededDepartment from Dock (blocks) Ratio Rank
1. Toasters 280 1 280/1 = 280 22. Air conditioners 160 2 160/2 = 80 63. Microwaves 360 1 360/1 = 360 14. Stereos 375 3 375/3 = 125 55. TVs 800 4 800/4 = 200 36. Radios 150 1 150/1 = 150 47. Bulk storage 100 2 100/2 = 50 7
Example 10.3
Dock Aisle
Storage area
Storage area
A-1 Distribution A-1 Distribution SystemsSystems
Trips to and Area NeededDepartment from Dock (blocks) Ratio Rank
1. Toasters 280 1 280/1 = 280 22. Air conditioners 160 2 160/2 = 80 63. Microwaves 360 1 360/1 = 360 14. Stereos 375 3 375/3 = 125 55. TVs 800 4 800/4 = 200 36. Radios 150 1 150/1 = 150 47. Bulk storage 100 2 100/2 = 50 7
Example 10.3
Dock Aisle
Storage area
Storage area
A-1 Distribution A-1 Distribution SystemsSystems
Trips to and Area NeededDepartment from Dock (blocks) Ratio Rank
1. Toasters 280 1 280/1 = 280 22. Air conditioners 160 2 160/2 = 80 63. Microwaves 360 1 360/1 = 360 14. Stereos 375 3 375/3 = 125 55. TVs 800 4 800/4 = 200 36. Radios 150 1 150/1 = 150 47. Bulk storage 100 2 100/2 = 50 7
Example 10.3
Dock Aisle
Storage area
3
Storage area
A-1 Distribution A-1 Distribution SystemsSystems
Trips to and Area NeededDepartment from Dock (blocks) Ratio Rank
1. Toasters 280 1 280/1 = 280 22. Air conditioners 160 2 160/2 = 80 63. Microwaves 360 1 360/1 = 360 14. Stereos 375 3 375/3 = 125 55. TVs 800 4 800/4 = 200 36. Radios 150 1 150/1 = 150 47. Bulk storage 100 2 100/2 = 50 7
Example 10.3
Dock Aisle
Storage area
3
1
Storage area
A-1 Distribution A-1 Distribution SystemsSystems
Trips to and Area NeededDepartment from Dock (blocks) Ratio Rank
1. Toasters 280 1 280/1 = 280 22. Air conditioners 160 2 160/2 = 80 63. Microwaves 360 1 360/1 = 360 14. Stereos 375 3 375/3 = 125 55. TVs 800 4 800/4 = 200 36. Radios 150 1 150/1 = 150 47. Bulk storage 100 2 100/2 = 50 7
Example 10.3
Dock Aisle
Storage area
3
1
5 5
5 5
Storage area
A-1 Distribution A-1 Distribution SystemsSystems
Trips to and Area NeededDepartment from Dock (blocks) Ratio Rank
1. Toasters 280 1 280/1 = 280 22. Air conditioners 160 2 160/2 = 80 63. Microwaves 360 1 360/1 = 360 14. Stereos 375 3 375/3 = 125 55. TVs 800 4 800/4 = 200 36. Radios 150 1 150/1 = 150 47. Bulk storage 100 2 100/2 = 50 7
Figure 10.9
Dock Aisle
Storage area
3
1
5 5
5 5
6 4 2 7
4 4 2 7
Storage area
Zone SystemsZone Systems
Zone SystemsZone Systems
Shipping doors
Tractor trailer
Tractor trailer
Zones Zones
Figure 10.10
Zone SystemsZone Systems
Click to add titleZones Zones
Shipping doors
Tractor trailer
Tractor trailer
Feeder lines
Feeder lines
Figure 10.10
Zone SystemsZone Systems
Click to add titleZones Zones Control
station Shipping doors
Tractor trailer
Tractor trailer
Feeder lines
Feeder lines
Figure 10.10
Zone SystemsZone Systems
Click to add titleZones Zones Trunk lineControl
station Shipping doors
Tractor trailer
Tractor trailer
Overflow
Feeder lines
Feeder lines
Figure 10.10
Addison Wesley Addison Wesley Longman Distribution Longman Distribution CenterCenter
Line BalancingLine Balancing
Green Grass, Inc.Big Broadcaster
Line BalancingLine BalancingBig Broadcaster
Line BalancingLine BalancingBig Broadcaster
A Bolt leg frame to hopper 40 NoneB Insert impeller shaft 30 AC Attach axle 50 AD Attach agitator 40 BE Attach drive wheel 6 BF Attach free wheel 25 CG Mount lower post 15 CH Attach controls 20 D, EI Mount nameplate 18 F, G
Total 244
Work Time ImmediateElement Description (sec) Predecessor(s)
Example 10.4
Line BalancingLine BalancingBig Broadcaster
A Bolt leg frame to hopper 40 NoneB Insert impeller shaft 30 AC Attach axle 50 AD Attach agitator 40 BE Attach drive wheel 6 BF Attach free wheel 25 CG Mount lower post 15 CH Attach controls 20 D, EI Mount nameplate 18 F, G
Total 244
Work Time ImmediateElement Description (sec) Predecessor(s)
Example 10.4
Line BalancingLine BalancingBig Broadcaster
A Bolt leg frame to hopper 40 NoneB Insert impeller shaft 30 AC Attach axle 50 AD Attach agitator 40 BE Attach drive wheel 6 BF Attach free wheel 25 CG Mount lower post 15 CH Attach controls 20 D, EI Mount nameplate 18 F, G
Total 244
Work Time ImmediateElement Description (sec) Predecessor(s)
40
A
Example 10.4
Line BalancingLine BalancingBig Broadcaster
A Bolt leg frame to hopper 40 NoneB Insert impeller shaft 30 AC Attach axle 50 AD Attach agitator 40 BE Attach drive wheel 6 BF Attach free wheel 25 CG Mount lower post 15 CH Attach controls 20 D, EI Mount nameplate 18 F, G
Total 244
Work Time ImmediateElement Description (sec) Predecessor(s)
40
30
B
A
Example 10.4
Line BalancingLine BalancingBig Broadcaster
A Bolt leg frame to hopper 40 NoneB Insert impeller shaft 30 AC Attach axle 50 AD Attach agitator 40 BE Attach drive wheel 6 BF Attach free wheel 25 CG Mount lower post 15 CH Attach controls 20 D, EI Mount nameplate 18 F, G
Total 244
Work Time ImmediateElement Description (sec) Predecessor(s)
40
50
B
C
A
30
Example 10.4
Line BalancingLine BalancingBig Broadcaster
A Bolt leg frame to hopper 40 NoneB Insert impeller shaft 30 AC Attach axle 50 AD Attach agitator 40 BE Attach drive wheel 6 BF Attach free wheel 25 CG Mount lower post 15 CH Attach controls 20 D, EI Mount nameplate 18 F, G
Total 244
Work Time ImmediateElement Description (sec) Predecessor(s)
40
50
30
40
D
B
C
A
Example 10.4
Line BalancingLine BalancingBig Broadcaster
A Bolt leg frame to hopper 40 NoneB Insert impeller shaft 30 AC Attach axle 50 AD Attach agitator 40 BE Attach drive wheel 6 BF Attach free wheel 25 CG Mount lower post 15 CH Attach controls 20 D, EI Mount nameplate 18 F, G
Total 244
Work Time ImmediateElement Description (sec) Predecessor(s)
40
6
50
E30
40
D
B
C
A
Example 10.4
Line BalancingLine BalancingBig Broadcaster
A Bolt leg frame to hopper 40 NoneB Insert impeller shaft 30 AC Attach axle 50 AD Attach agitator 40 BE Attach drive wheel 6 BF Attach free wheel 25 CG Mount lower post 15 CH Attach controls 20 D, EI Mount nameplate 18 F, G
Total 244
Work Time ImmediateElement Description (sec) Predecessor(s)
40
6
50
E30
25
40
D
B
FC
A
Example 10.4
Line BalancingLine BalancingBig Broadcaster
A Bolt leg frame to hopper 40 NoneB Insert impeller shaft 30 AC Attach axle 50 AD Attach agitator 40 BE Attach drive wheel 6 BF Attach free wheel 25 CG Mount lower post 15 CH Attach controls 20 D, EI Mount nameplate 18 F, G
Total 244
Work Time ImmediateElement Description (sec) Predecessor(s)
40
6
50
15
E30
25
40
D
B
FC
A
G
Example 10.4
Line BalancingLine BalancingBig Broadcaster
A Bolt leg frame to hopper 40 NoneB Insert impeller shaft 30 AC Attach axle 50 AD Attach agitator 40 BE Attach drive wheel 6 BF Attach free wheel 25 CG Mount lower post 15 CH Attach controls 20 D, EI Mount nameplate 18 F, G
Total 244
Work Time ImmediateElement Description (sec) Predecessor(s)
40
6
20
50
15
E30
25
40H
D
B
FC
A
G
Example 10.4
Line BalancingLine BalancingBig Broadcaster
A Bolt leg frame to hopper 40 NoneB Insert impeller shaft 30 AC Attach axle 50 AD Attach agitator 40 BE Attach drive wheel 6 BF Attach free wheel 25 CG Mount lower post 15 CH Attach controls 20 D, EI Mount nameplate 18 F, G
Total 244
Work Time ImmediateElement Description (sec) Predecessor(s)
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
Example 10.4
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
Figure 10.11
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
Desired output rate = 2400/weekPlant operates 40 hours/week
Example 10.5
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
Desired output rate = 2400/weekPlant operates 40 hours/week
r = 2400/40 = 60 units/hour
Example 10.5
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
Desired output rate = 2400/weekPlant operates 40 hours/week
r = 2400/40 = 60 units/hour
c = 1/60 = 1 minute/unit= 60 seconds/unit
Example 10.5
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
Desired output rate = 2400/weekPlant operates 40 hours/week
c = 60 seconds/unit
Example 10.5
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
Desired output rate = 2400/weekPlant operates 40 hours/week
c = 60 seconds/unit
TM = 244 seconds/60 seconds= 4.067 or 5 stations
Example 10.5
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
Desired output rate = 2400/weekPlant operates 40 hours/week
TM = 244 seconds/60 seconds= 4.067 or 5 stations
Efficiency = [244\5(60)]100 = 81.3%
c = 60 seconds/unit
Example 10.5
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Cumm IdleStation Candidate Choice Time Time
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Cumm IdleStation Candidate Choice Time Time
S1 A A 40 20
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Cumm IdleStation Candidate Choice Time Time
S1 A A 40 20
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Cumm IdleStation Candidate Choice Time Time
S1 A A 40 20
S1
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Cumm IdleStation Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10
S1
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Cumm IdleStation Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10
S1
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Cumm IdleStation Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10
S1
S2
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Cumm IdleStation Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10
S3 B,F,G B 30 30
S1
S2
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Cumm IdleStation Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10
S3 B,F,G B 30 30
S1
S2
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Cumm IdleStation Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10
S3 B,F,G B 30 30
S1
S2
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Cumm IdleStation Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10
S3 B,F,G B 30 30E,F,G F 55 5
S1
S2
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Cumm IdleStation Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10
S3 B,F,G B 30 30E,F,G F 55 5
S1
S2
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
Cumm IdleStation Candidate Choice Time Time
S1 A A 40 20
S2 B,C C 50 10
S3 B,F,G B 30 30E,F,G F 55 5
S1
S2S3
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
S1
S2S3
Example 10.6
Line BalancingLine BalancingBig Broadcaster
40
6
20
50
15
18
E30
25
40H
I
D
B
FC
A
G
c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%
S1
S2S3
S5S4
Figure 10.12