Minggu14 Keseimbangan Lintas Perakitan (Modif)
Minggu14 Keseimbangan Lintas Perakitan (Modif)
Minggu14 Keseimbangan Lintas Perakitan (Modif)
Hasil Pembelajaran
Umum
Mahasiswa mampu menerapkan model matematik,
heuristik dan teknik statistik untuk menganalisis dan
merancang suatu sistem perencanaan dan pengendalian
produksi
Khusus
Memahami konsep keseimbangan lintasan
2
Various Objects
Part: is composed of a single material and is an individual part of the
product
Component: ranges from a part to a combination of parts which are
included in the product
Building block: a composite part of the product which because of assembly
requirements represents a sub-assembly
Base component: a (larger) component onto which others are assembled
Formless material: e.g. viscose components such as glue, paint, liquids
Sub-assembly: one component is assembled with another component, a
base component or building block
Final assembly: describes the construction of a building block or the
finished product
3
Exploded Assembly
4
Assembly Example
5
The assembly of a joint
6
The concept of sub and final assembly
7
Step by step assembly
8
An integrated approach
9
Fabrication/Assembly Line
10
Fabrication/Assembly Line
A production/fabrication line builds components on a series of machines
An assembly line puts the fabricated parts together at a series of
workstations
Both are repetitive processes and in both cases, the line must be balanced
Fabrication lines tend to be machine-paced and require mechanical and
engineering changes to facilitate balancing
Assembly lines tend to be paced by work tasks assigned to individuals or
workstations
Assembly lines therefore can be balanced by moving task form one
individual or workstation to another. In this manner, the amount of time
required by each individual or workstation is equalized
11
Assembly Line Balancing
Assembly line is a production line in which material moves continuously at
a uniform average rate through a sequence of workstations where assembly
work is performed
Assembly accounts for between 40-60% of the total production time
Down time of an assembly line costs a major car manufacturer $98,000 per
minute
Line balancing is usually done to minimize imbalance between
individual/machine/workstation while meeting a required output from the
line
Problems in assembly lines: balancing the workstations and keeping the
assembly line in continuous production
12
Types of assembly line balancing
problems
Simple assembly line balancing type I (SALB-I): is to
determine the minimal number of workstations necessary to
maintain the production rate (1/CT) while observing the
precedence constraints
13
Definitions(1)
Assembled product: the product that passes through a sequence of
workstations where tasks are performed on the product until it is completed
at the final workstation. The throughput of the assembly line is measured
by the number of assembled products per unit time
Work element: a part of the total work content in an assembly process.
N: The total number of work elements required to complete the assembly
i: the work element number in the process (1i N)
Workstation (WS): a location on the assembly line where a work element
or elements are performed on the product.
K denotes the minimum number of workstations, K1
14
Definitions(2)
Cycle time (CT): the time between the completion of 2
successive assemblies, assumed constant for all assemblies for
a given conveyor speed. Conveyors are the key material
movers in most assembly lines: belt, chain, overhead,
pneumatic, and screw conveyors
T T= production time available per day
CT d= demand per day or production per day
d
Station time (ST): the sum of the times of work elements that
are performed at the same workstation. STCT
Delay/idle time of a workstation: the difference between the
cycle time (CT) and the station time (ST). D=CT-ST
15
Definitions(3)
16
Definitions(4)
Perfect balance means to combine the elements of work to be done in such
a manner that at each station the sum of the elemental times just equals the
cycle time (D=CT-ST=0)
Line efficiency (LE): the ratio of total station time to the cycle time
multiplied by the number of workstations
K
SI is expressed as
K
SI max i
( ST
i 1
ST ) 2
18
Contoh 1
5 5 1 7
1 6 9 12
3 6 4 4
4 5 10 11
19
Metode Assembly Line Balancing
1. Kilbridge-Western Heurustic
2. Helgeson Birnie
3. The Largest Candidate rule
4. Model Matematik
5. D.l.l.
20
Kilbridge-Weston Heuristic(1)
21
Kilbridge-Weston Heuristic(2)
3 4 2 6
2 3 7 8
5 5 1 7
1 6 9 12
3 6 4 4
4 5 10 11
I II III IV V VI VII
22
Kilbridge-Weston Heuristic(3)
2. Tentukan waktu siklus (CT) dari bilangan prima waktu total elemen kerja
m
, dan tentukanjumlah
t
i 1
stasiun kerja
i
t m
t
i
K i 1
= 50 i
CT i 1
23
Kilbridge-Weston Heuristic(4)
24
Kilbridge-Weston Heuristic(5)
Salah satu solusi feasible untuk Contoh 1 adalah:
Work Station Elemen Waktu stasiun (ST)
I 1 5
II 2 dan 4 6
III 3 dan 5 10
IV 6 5
V 7, 9, dan 10 7
VI 8 dan 11 10
VII 12 7
25
Kilbridge-Weston Heuristic(6)
27
Kilbridge-Weston Heuristic(8)
28
Metoda Helgeson-Birnie(1)
29
Metoda Helgeson-Birnie(2)
Contoh:
Diketahui precedence diagram seperti pada Gambar 10.15 berikut.
Tentukan line balancing dan smoothness indeksnya dengan metode
Helgeson-Birnie?
3 4 2 6
2 3 7 8
5 5 1 7
1 6 9 12
3 6 4 4
4 5 10 11
30
3 4 2 6
2 3 7 8
5 5 1 7
Metoda Helgeson-Birnie(3) 1 6 9 12
3 6 4 4
4 5
SOLUSI 10 11
32
3 4 2 6
2 3 7 8
5 5 1 7
Metoda Helgeson-Birnie(5) 1 6 9 12
3 6 4 4
4 5 10 11
33
The Largest Candidate Rule (1)
Algoritma largest candidate rule yaitu sebagai
berikut:
1. List semua elemen kerja berdasarkan waktu elemen kerja terbesar.
2. Mulai dari urutan teratas list, pilih elemen pertama yang memenuhi
kriteria precedence diagram dan tidak menyebabkan total waktu
elemen kerja melebihi waktu stasiun maksimum.
3. Ketika sebuah elemen ditugaskan, mulai kembali dari urutan teratas
1-2, dan dipilih kembali elemen.
4. Ketika tidak ada elemen yang bisa ditugaskan kembali, proses ke
stasiun kerja selanjutnya.
5. Ulangi ke step 1.) dan 2.) sampai semua elemen kerja ditugaskan.
34
The Largest Candidate Rule (2)
Contoh
Diketahui precedence diagram berikut seperti pada Gambar
10.16. Tentukan line balancing dan smoothness indeksnya
dengan metode Largest Candidate Rule?
3 4 2 6
2 3 7 8
5 5 1 7
1 6 9 12
3 6 4 4
4 5 10 11
35
3 4 2 6
2 3 7 8
The Largest Candidate Rule (3) 5 5 1 7
1 6 9 12
List semua elemen kerja berdasarkan waktu 3 6 4 4
elemen kerja terbesar 4 5 10 11
3 6 4 4
4 5 10 11
Hasil Urutan berdasarkan algoritma larges candidate rule
I 1 5
2 3 8
II 3 4
4 3 7
III 5 6 6
IV 6 5
10 4 9
V 11 4
7 2 6
VI 8 6
9 1 7
VII 7 7
37
The Largest Candidate Rule (5)
Hasil Urutan berdasarkan algoritma larges candidate
rule
Stasiun Kerja Elemen Kerja Waktu elemen kerja Waktu stasiun
I 1 5
K
2 3 8 ST i
LE i 1
x100%
II 4 3 ( K )(CT )
3 4 7
=50(7)(10)x100%=
III 5 6 6 71,43%
IV 6 5
10 4 9 K
V 11 4
SI ( ST
i 1
max STi ) 2
7 2 6
VI 8 6 = 31=5.57
9 1 7
VII 7 7
38
Metoda The Largest Candidate
Rule(6)
Contoh:
Diketahui precedence diagram seperti ditunjukkan pada
Gambar 10.17. Tentukan line balance ng dan smoothness
indeksnya dengan metode The Largest Candidate?
39
Elemen Waktu
kerja
Metoda The Largest elemen
kerja Predecessor
Candidate Rule(7) 1
0.2 -
2
0.4 -
Solusi: 3
0.7 1
Elemen Kerja 4
0.1 1,2
5
0.3 2
6
0.11 3
7
0.32 3
8
0.6 3,4
9
0.27 6,7,8
10
0.38 5,8
11
0.5 9,10
Stmax = 0.7 12
t = 4.0 0.12 11
4.0 40
Elemen waktu
Metoda The Largest kerja elemen
kerja predecessor
Candidate Rule(7) 3
0.7 1
8
Hasil Urutan 0.6 3,4
11
0.5 9,10
2
0.4 -
10
0.38 5,8
7
0.32 3
5
0.3 2
9
0.27 6,7,8
1
0.2 -
12
0.12 11
6
0.11 3
4
0.1 1,2
41
Metoda The Largest Candidate Rule(7)
Penyusunan stasiun kerja
Stasiun Elemen Waktu Waktu
Kerja Kerja elemen kerja stasiun
1 2 0.4
5 0.3
K
ST i
1 0.2 LE i 1
( K )(CT )
x100%
( ST max STi ) 2
10 0.38 0.98 i 1
4 7 0.32 = 0.349=0.591
9 0.27 0.59
5 11 0.5
12 0.12 0.62
42
Metoda The Largest Candidate Rule(8)
Pembagian elemen kerja
43
44
Mathematical model(1)
45
Mathematical model(2)
46
Mathematical model(3)
47
Mathematical model(4)
48
Mathematical model(5)
49
Mathematical model(6)
50
Mathematical model(7)
51
Mathematical model(8)
52
Mathematical model(9)
53
Mathematical model(10)
54
Mathematical model(11)
55