Multiple Product Assembly

Line Design

Multiple Product Assembly Lines

More than one product (model) sharing the same facility
Zoning
Designated zone on line for each model

Parallel Lines
One line for each major model balanced by itself

Multi-product Lines
Different models produced one-set-at-a-time in batches on same
line, each balanced independently

Mixed Model Lines

Different models produced in frequently alternating sequence
based on some logic
Aggregate Balancing followed by Model Sequencing

Sequential Processing of Multiple Products

Zoning
Products

Customer
order

Completed
orders
Order/product flow

Parallel Lines for Variants

Implications relating to
Tooling and
equipment duplication
Degree of variability in
timings/ demand
Material handling and
positioning

Balancing Mixed Model Lines

Notation (adapted as per Mondens Goal Chasing algorithm)
T: Balancing period (over which model mix repeats cyclically)
i: Model index (i = 1, , Number of models)
Qi: Number of units of model i produced in period T
Q: Total production in period T, = i Qi
tie: Time required for element e on model i
Trade-offs in choice of balancing period?

Balancing Approach (Thomopoulos)

1.

Construct combined precedence diagram covering all

models (element times may vary across models, may
even be 0 on some models)

2.

Consider cycle time c = T / Q

3.

Consider element time te = (i Qi tie) / Q

4.

Balance using Single Model techniques, seeking to

minimize total idle time across stations, = Nc - e te
i.e. sum of cycle times over all stations less total
weighted element times

Multiple Model Line Balancing

Example

Example Data: Medical Kit Packing

System works 40 hrs./ week (60 mins./ hr., 60 secs./min.)

Aggregate output required: 6000 per week

Example Calculations ..

Target cycle time = Available Time/ Output required = 40*60*60/6000 = 24 sec .

Nmin = Composite work content/ Cycle time = 106.1/24 = 4.42 ~ 5

.. Example Representation & Calculations

Op.

Avg.
Duration

Positional
Weight

14.1

106.1

9.0

80.4

6.7

78.1

4.9

76.3

7.4

71.4

19.2

51.6

4.8

37.2

7.6

40.0

10.0

32.4

22.4

22.4

Positional
weight for
an individual
operation is
the sum of
its average
task time
plus the
task times
of all its
successors
in the
network

Example Work Allocation

23.1

19.2
22.4

Eligibl
e
Operat
ion(s)

Select
ed
Opera
tion(s)

Compo
site
Operati
on
Time

Assign
ed to
Station

Cumulat
ive Time
Assigne
d

14.1

14.1

Idle
Time

0.9

23.8

17.6

Balance Delay Ratio = Total Idle Time x 100

Available time on line
= (0.9+0.2+4.8+6.4+1.6)/(5*24)
= 13.9/ 120 = 11.6%

B, C,D

9.0

23.1

C, D

6.7

II

6.7

4.9

II

11.6
0.2

7.4

II

19.0

F, G,
H

G
(only
fit)

4.8

II

23.8

F, H

19.2

III

19.2

7.6

IV

7.6

4.8
6.4

10.0

IV

17.6

22.4

22.4

1.6