While the engine installation crew works on the second car, the first car can be moved to the hood station and fitted with a hood, then to the wheels station and be fitted with wheels. By having three stations, three cars can be operated on at the same time, each at a different stage of assembly.Īfter finishing its work on the first car, the engine installation crew can begin working on the second car. When a station is finished with a car, it passes it on to the next. In an assembly line, car assembly is split between several stations, all working simultaneously. If engine installation takes 20 minutes, hood installation takes five minutes, and wheels installation takes 10 minutes, then a car can be produced every 35 minutes. In traditional production, only one car would be assembled at a time. Motor assembly line at Willys-Overland Company, Toledo, Ohio, 1920Ĭonsider the assembly of a car: assume that certain steps in the assembly line are to install the engine, install the hood, and install the wheels (in that order, with arbitrary interstitial steps) only one of these steps can be done at a time. Major planning problems for operating assembly lines include supply chain integration, inventory control and production scheduling. not putting in a screw before drilling the hole) and (2) a cycle time which restricts the sum of task processing times which can be completed at each workstation before the work-piece is moved to the next station by the conveyor belt. The assignment of tasks to stations is typically limited by two constraints: (1) a precedence graph which indicates what other tasks need to be completed before a particular task can be initiated (e.g. Each task requires a given task duration for completion. ![]() In the simple assembly line balancing problem the aim is to assign a set of tasks that need to be performed on the workpiece to a sequence of workstations. ĭesigning assembly lines is a well-established mathematical challenge, referred to as an assembly line balancing problem. (3) Use sliding assembling lines by which the parts to be assembled are delivered at convenient distances. (2) Use work slides or some other form of the carrier so that when a workman completes his operation, he drops the part always in the same place-which place must always be the most convenient place to his hand-and if possible have gravity carry the part to the next workman for his own. (1) Place the tools and the men in the sequence of the operation so that each component part shall travel the least possible distance while in the process of finishing. ![]() ![]() Each worker typically performs one simple operation unless job rotation strategies are applied. Heavy lifting is done by machines such as overhead cranes or forklifts. All parts or assemblies are handled either by conveyors or motorized vehicles such as fork lifts, or gravity, with no manual trucking. The motion of workers is minimized to the extent possible. Assembly lines are designed for the sequential organization of workers, tools or machines, and parts.
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