Model Answer
0 min readIntroduction
Line balancing is a crucial technique in operations management aimed at distributing workload evenly across workstations in a production line. It seeks to minimize idle time and maximize throughput, ultimately enhancing efficiency and reducing production costs. The goal is to achieve a smooth flow of work, ensuring that no workstation becomes a bottleneck. A key parameter in line balancing is the cycle time, which represents the maximum time allowed at each workstation to complete its assigned tasks. This answer will demonstrate a line balancing exercise for a 60-second cycle time, assuming a set of hypothetical tasks and their associated processing times.
Understanding Line Balancing and Cycle Time
Line balancing involves assigning tasks to workstations in a way that minimizes the difference in workload between them. The cycle time is a critical determinant of the line’s efficiency. It’s the time interval at which a finished product comes off the assembly line. A shorter cycle time generally implies higher production rates, but it also requires more efficient workstation assignments.
Hypothetical Task List and Times
To illustrate line balancing, let's assume the following tasks and their processing times (in seconds):
| Task | Processing Time (seconds) |
|---|---|
| A | 10 |
| B | 15 |
| C | 8 |
| D | 12 |
| E | 20 |
| F | 5 |
| G | 18 |
| H | 7 |
| I | 13 |
| J | 9 |
Line Balancing Procedure
- Calculate Total Task Time: The total time required to complete all tasks is 10 + 15 + 8 + 12 + 20 + 5 + 18 + 7 + 13 + 9 = 117 seconds.
- Determine Theoretical Minimum Number of Workstations: Total Task Time / Cycle Time = 117 / 60 = 1.95. Therefore, we need at least 2 workstations.
- Assign Tasks to Workstations: The goal is to assign tasks to workstations such that the total processing time at each workstation does not exceed the cycle time (60 seconds). We will use a trial-and-error approach, prioritizing tasks with longer processing times.
Proposed Line Balancing Assignment
Here’s a possible line balancing assignment:
| Workstation | Tasks Assigned | Total Time (seconds) |
|---|---|---|
| Workstation 1 | E (20) + A (10) + F (5) + C (8) + H (7) | 50 |
| Workstation 2 | G (18) + B (15) + D (12) + J (9) + I (13) | 67 |
As you can see, Workstation 2 exceeds the cycle time of 60 seconds. We need to re-allocate tasks.
Revised Line Balancing Assignment
A more balanced assignment would be:
| Workstation | Tasks Assigned | Total Time (seconds) |
|---|---|---|
| Workstation 1 | E (20) + A (10) + F (5) + C (8) | 43 |
| Workstation 2 | G (18) + B (15) + D (12) | 45 |
| Workstation 3 | J (9) + I (13) + H (7) | 29 |
This revised assignment requires 3 workstations. Workstation 1 has 17 seconds of idle time, Workstation 2 has 15 seconds of idle time, and Workstation 3 has 31 seconds of idle time. This is a more balanced distribution of workload.
Considerations and Limitations
This example is simplified. In a real-world scenario, factors like precedence constraints (some tasks must be completed before others), task dependencies, and worker skill levels would need to be considered. Furthermore, the assignment assumes that tasks cannot be split between workstations. More sophisticated line balancing techniques, such as computerized algorithms, are often used to optimize the assignment process.
Conclusion
Effective line balancing is essential for optimizing production efficiency and minimizing costs. Achieving a balanced line with a 60-second cycle time, as demonstrated, requires careful consideration of task times and a systematic approach to task assignment. While the example presented is hypothetical, it illustrates the core principles of line balancing. Real-world applications often involve more complex scenarios and necessitate the use of advanced optimization techniques to achieve optimal results.
Answer Length
This is a comprehensive model answer for learning purposes and may exceed the word limit. In the exam, always adhere to the prescribed word count.