Line balancing example in a Mass customization environment

1. Engine Unit Module Project 1/11
author: Russell Sims
date: May 28, 2008
Project Description
Main Deliverables of the Project
1. To provide C9 and C13 engine modules to the SpeedLine at a rate to satisfy takt
time during maximum customer demand cycles.
2. Engine Unit shall maintain a buffer to feed the SpeedLine of not less than 1 and
no more than 3 engine unit of each type.
Customer of the Project
1. Customer of this project is the SpeedLine in general and specifically station 2 of
the SpeedLine.
Scope of the Project
1. This project shall encompass all engine models produced for Lokotracks in the
Columbia Manufacturing facility.
2. Current product mix consists of C13 Modules for LT200HP and C9 Modules for
LT106. We are currently forecast to build LT1213 and LT1213S Lokotracks which
will take a slightly Modified C13 Module.
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2. Engine Unit Module Project 2/11
author: Russell Sims
date: May 28, 2008
Structure of the Project
Time
Study
Make/Buy
Anaysis
Layouts Sub
and assembly
Balancing breakouts
Project Classification
1. This Project is unclassified and contains no confidential data.
Project Owner
1. LT Manufacturing Engineer is the owner of this project
Project Manager
1. Russell Sims is the LT Implementation Project Manager.
Required Human Resources (Internal)
1. Engine Module Assembly Team consisting of 1 team leader, five team members
and a material services person.
2. Supervisor element

3. Engine Unit Module Project 3/11
author: Russell Sims
date: May 28, 2008
Required Human Resources (External)
1. Intern for data collection
Other Required Resources
1. Material handling equipment, IT services, tools and tool boxes, communications
devices, maintenance support.
Product Mix
Monthly Monthly Daily
Annual average max. max.
demand demand Daily average demand demand demand
LT106 C-9 140 11.7 0.56 20 0.95
LT1213 / -S C-13 110 9.2 0.44 15 0.71
LT200HP C-13 100 8.3 0.40 25 1.19
Total demand 350 29.2 60
days
Annual time available 220 hours
Monthly time available 21 Total assembly process time 24
Planned takt timemin 5.03
hrs/month
Time available in 1
shift 168 Calculated number of stages 4.8
Time available in 2 Selected number of stages
shifts 336 (takts) 5
Time available in 3
shifts 504
hours
Annual time available 1760
Monthly time available 168
Line takt timemin 5.03
unit/hour
Line speedmax 0.20

4. Engine Unit Module Project 4/11
author: Russell Sims
date: May 28, 2008
Product Architecture Review
Demand Rates & Available Time
Monthly Daily Monthly Daily
Annual average average max. max.
demand demand demand demand demand
LT106 C-9 140 11.7 0.56 20 0.95
LT1213/LT1213S C-13 110 9.2 0.44 15 0.71
LT200HP C-13 100 8.3 0.40 25 1.19
Total demand 350 29.2 60
days
Annual time available 220
Monthly time available 21
hrs/month
Time available in 1 shift 168
Time available in 2 shifts 336
Time available in 3 shifts 504

5. Engine Unit Module Project 5/11
author: Russell Sims
date: May 28, 2008
Line Design : Takt timemin and Line speedmax
1. Takt time is the pace of production to match the rate of customer demand.
2. Takt time is the heartbeat of the whole production system
Formula:
Monthly
Annual average Takt timemin = Time available/Total demand
demand demand
LT106 C-9 140 11.7 Line Speedmax =1/Takt time
LT1213/ LT1213S C-13 110 9.2
LT200HP C-13 100 8.3
Example:
Total demand 350 29.2 Takt timemin = 1760 h/350 units =5.02 h
hours Line Speedmax =1/2.03 h = 0.20 unit/h
Annual time available 1760
Monthly time available 168 (Note) This line design calculation is based on
production mainly in one shift)
Line takt timemin 5.03
unit/hour Line Design
Line speedmax 0.20
Product-specific high season demand rates
Product-specific demand rate for materials
Monthly
Annual max. planning formula:
demand demand
LT106 C-9 Rate = Product Demand/days of planning
140 20 period
LT1213/ LT1213S C-13
110 15 Example High Season Rate for LT106 C-9
LT200HP C-13
100 25
Rate = 20 pcs/21 days = 0.95 pcs/day
Total demand
350 80

6. Engine Unit Module Project 6/11
author: Russell Sims
date: May 28, 2008
Annual Monthly average
demand demand
LT106 C-9 140 11.7
LT1213 / -S C-13 110 9.2
LT200HP C-13 100 8.3
Total demand 350 29.2
unit/hour
Line speedmax 0.20
hrs/month unit/month
Time available in 1 shift 168 33 Line outputmax in 1 shift
Time available in 2 Line outputmax in 2
shifts 336 67 shifts
Time available in 3 Line outputmax in 3
shifts 504 101 shifts
Formula:
Line outputmax = Available timemax x Line Speedmax
Example: In 2 shift time available 336 h/month.
Line speedmax=0, 20 unit/h (takt time 5.03 h)
Max. Line output in 2-shift= 336 x 0, 20 = 67 units/month
Needed daily run hours = Total demand / Line Speedmax
Example: Demand 50 unit/month
Needed run hours = 50/0.20=250 h/month = 11.9 h/day
Two Shifts Needed During High Season

7. Engine Unit Module Project 7/11
author: Russell Sims
date: May 28, 2008
Fast and Slow Options
1. There are no fast or slow options currently available for the engine modules. We
will revisit this subject if the need arises.
Consumption Rate for Fast Options
1. There are no fast options currently available for the engine modules. We will
revisit this subject if the need arises.
Minimum Lead Time from Work Order to Assembly
Work Order
Recieved Engine Mounted on
(SpeedLine) Lokotrack
Minimum Lead Time 2.5 D
Minumum Customer response time 3.5 D
Split Minimum SpeedLine Lead Time into Sub-process Lead Times
Work Order
Recieved Engine Mounted on
(SpeedLine) Lokotrack
Minimum Lead Time 2.5 D 3 Stage production needed
based on lead times and
Minumum Customer response time 3.5 D
throughput calculations
Sub assembly Station 2 Testing
Station 3
1.05 D .66 D .5 D
.71 D

8. Engine Unit Module Project 8/11
author: Russell Sims
date: May 28, 2008
Preliminary Line Balancing
500
Engine warm-up/Hydraulic Test
450 Electrical Test
Electrical connection
400
Hydraulic connection
350 Priming Deisel
Hydraulic oil
300 Bottom Plates (2)
Ball Valves (2)
250
Exhaust
200 Door Work
Fuel Water Sep
150 Fuel Cooler
Turbo Tube
100
Hood Bar
50 Hood Prep
Radiator Bar/Light Mast
0 Oil Fill **
Sub Assembly Sta 2 Man 1 Sta 2 Man 2 Sta 3 Man 1 Sta 3 Man 2 Testing Required Time
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9. Engine Unit Module Project 9/11
author: Russell Sims
date: May 28, 2008
Preliminary Assembly Flowchart
•Mechanical Assembly 3.12h
Sub •Electrical Assembly .58h
•Coolant Assembly 2.48h
Assembly •Hood Assembly .53h
•Tank Assembly 1.72h
•Wiring 3.03h Meeting
Station 2 •Hose Assembly 1.06h
•Tank Installation .52h Customer
•Exhaust .48h
Demand
•Bottom Plates .5h
•Platforms .33h
Station 3 •Turbo Tube .63h
•Oil Fill 1h
•Intake Radiator .72h
•Test the Engine Unit 2.5h
Testing •Minor Adjustments .5h

10. Engine Unit Module Project 10/11
author: Russell Sims
date: May 28, 2008
Feeding process flowchart (synchronization)
Click here to follow link to actual data.

11. Engine Unit Module Project 11/11
author: Russell Sims
date: May 28, 2008
Needed manpower for each station and cell
Hours
Planned Takt
Time 7.167
Total
work
content Capacity Balancing
time Resource Resource available loss
[hours] needed allocated [hours] [hours]
Sub Assembly 6.7 0.9 2 0.0 -6.7
Station 2 11.5 1.6 4 0.0 -11.5
Station 3 11.2 1.6 1 0.0 -11.2
Test 1.9 0.3 2 0.0 -1.9
Total 31.3 4.4 9.0 0.0 -31.3