Assembly line planning and control

152 Pages·2014·3.309 MB·English

by  Nick T. Thomopoulos (auth.)

Nick T. Thomopoulos
Assembly Line
Planning and
Control
Assembly Line Planning and Control
Nick T. Thomopoulos
Assembly Line Planning
and Control
123
Nick T.Thomopoulos
Stuart Schoolof Business
IllinoisInstitute ofTechnology
Chicago, IL
USA
ISBN 978-3-319-01398-5 ISBN 978-3-319-01399-2 (eBook)
DOI 10.1007/978-3-319-01399-2
SpringerChamHeidelbergNewYorkDordrechtLondon
LibraryofCongressControlNumber:2013945141
(cid:2)SpringerInternationalPublishingSwitzerland2014
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methodology now known or hereafter developed. Exempted from this legal reservation are brief
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For my wife, my children and my
grandchildren
Preface
I was fortunate to have a rich and diverse career in industry and academia. This
includedworkingatInternationalHarvesterassupervisorofoperationsresearchin
the corporate headquarters;atIIT Research Institute(IITRI)asaSeniorScientist,
servingintheAdvanceAssemblyMethodsprogramwithworldwideapplications;
as a Professor in the Industrial Engineering Department at the Illinois Institute of
Technology (IIT); in the Stuart School of Business at IIT; and many years of
consulting assignments with industry and government throughout the world. At
IIT, I was lucky to be assigned a broad array of courses, gaining a wide breadth
with the variety of topics, and with the added knowledge I acquired with every
repeat of the course. I was also privileged to serve as the Advisor to many bright
Ph.D. students as they carried on their dissertation research. Bits of knowledge
from various courses and research helped me in the classroom, and also in my
consultingassignments.Iusedmyindustryknowledgeinclassroomlecturessothe
studentscouldseehowsomeofthetextbookmethodologiesactuallyareappliedin
industry.Atthesametime,theknowledgeIgainedfromtheclassroomhelpedme
to formulate and develop solutions to industry assembly line applications as they
unfolded. This variety of experience allowed me to view how assembly systems
areused inindustry.Thisbookisbasedonthistotalexperienceandalsoincludes
the quantitative methods that I found doable and useful.
Thanks especially to my wife, Elaine Thomopoulos, who encouraged me to
writethisbook,andwhogaveconsultationwheneverneeded.Thanksalsotomany
peoplewhohavehelpedandinspiredmeovertheyears.Icannameonlyafewhere.
These are: Robert Battaglia, Corning Glass; Sven Berg, L. M. Ericsson; Harry
Bock, Florsheim Shoe Company; Fred Bock, IITRI; Randy Braun, Komatsu-
Dresser; Toemchai Bunnag, PTT Public; John Cada, Florsheim Shoe Company;
MichelChaussumien,Citroen;JanisChurch,IITRI;CharlesClerval,Citroen;John
DeMotts, International Harvester; Ralph Edgington, NCR; Jim Gleason, Interna-
tionalHarvester;ScottHaligas,FlorsheimShoeCompany;AlHawkes,IITRI;Joe
Hoffman, Springfield Remanufacturing Corporation; Linkert Horn, IBM; Maurice
Kilbridge, Harvard University; Jack Kornfield, IITRI; Melvin Lehman,
Loyola University; Ronald Lodewyk, California State University, Turlock; Nico
Mantelli, Olivetti; Craig Marecek, Komatsu-Dresser; Joe Moore, IITRI; Chad
Myers, Springfield Remanufacturing Corporation; Jerry Novak, IITRI; Paul
O’Donnell, Westinghouse; Dino Olivetti, Olivetti; Stylianos Papaioannou,
vii
viii Preface
Lapin House; Ernest Pirone, IITRI; Ted Prenting, Marist College; Serge
Rhandhava,IITRI;HarryRindeskar,ASEA;WalterRyder,UniversityofSouthern
California; Ryan Stack, Springfield Remanufacturing Corporation; John Storto,
IITRI; Marvin Sussman, International Harvester; Ola Tannous, Electro Motive
Diesel;TorWadell, ASEA; Leon Wester, IITRI; and CharlesWright,Navistar.
Nick T. Thomopoulos
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Review of the Chapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Assembly Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
History of Assembly Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Type of Assembly Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3 Some Fundamentals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Work Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Precedence Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Unit Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Shift Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Shift Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Number of Operators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cycle Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Average Operator Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Balance Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Efficiency Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Line Balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Operator Times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Effective Cycle Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Effective Balance Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Bill of Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Part Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Stations and Operators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Main Line, Subassembly Lines, and Labor Groups . . . . . . . . . . . . . . 22
Parallel Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ix
x Contents
4 Assembly Planning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Single Model Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Labor Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Mixed Model Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Single Model Assembly with One Labor Group . . . . . . . . . . . . . . . . 27
Single Model Assembly with Five Labor Groups . . . . . . . . . . . . . . . 29
Mixed Model Make-to-Stock Assembly. . . . . . . . . . . . . . . . . . . . . . 30
Mixed Model Make-to-Stock Assembly with 2 Labor Groups. . . . . . . 34
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5 Inventory Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Single Model Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Mixed Model Make-to-Stock Assembly. . . . . . . . . . . . . . . . . . . . . . 38
Mixed Model Make-to-Order Assembly. . . . . . . . . . . . . . . . . . . . . . 40
When Same Part for all Options of Feature f . . . . . . . . . . . . . . . . . . 40
When Different Part for Each Option of Feature f. . . . . . . . . . . . . . . 41
Inventory Replenishments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Part Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Order Point and Order Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Buy Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6 Single Model Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Number of Operators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Some Measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Predecessor Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Precedence Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Line Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Effective Line Measures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Bill-of-Material Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Shift Inventory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Sequence of the Elements and Parts. . . . . . . . . . . . . . . . . . . . . . . . . 54
Just-in-Time Replenishments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
7 Mixed Model Make-to-Stock Assembly. . . . . . . . . . . . . . . . . . . . . 57
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Precedence Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Mixed Model Shift Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Shift Element Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Number of Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Contents xi
Mixed Model Line Balancing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Operator Model Times. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8 Mixed Model Make-to-Order Assembly . . . . . . . . . . . . . . . . . . . . 69
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Make-to-Order Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Precedence Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Features and Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Element Shift Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Number of Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Efficiency. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Line Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
The Shift Job Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Shift Count of Feature Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Make-to-Order Sequencing Algorithm . . . . . . . . . . . . . . . . . . . . . . . 76
Make-to-Order Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Job Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Make-to-Order Replacement Algorithm . . . . . . . . . . . . . . . . . . . . . . 82
Drop Job 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Drop Job 23 and Replace with Job 66 . . . . . . . . . . . . . . . . . . . . . . . 83
Bill-of-Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Part Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
9 Postponement Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Work Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Features and Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Bill-of-Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
No Postponement (Make-to-Order Assembly). . . . . . . . . . . . . . . . . . 91
Shift Element Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Line Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Line Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Shift Part Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Full Postponement (Single Model Assembly) . . . . . . . . . . . . . . . . . . 95
Work Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Shift Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Line Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Shift Part Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Partial Postponement (Make-to-Stock Assembly). . . . . . . . . . . . . . . . 98
Work Elements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Shift Assembly Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Shift Element Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101