This document discusses the process of line balancing, which is determining the optimal physical arrangement of resources in a facility. The goal is to balance the workload so that each worker performs the same amount of work and no one is overburdened or waiting. The procedure involves identifying tasks and predecessors, determining the output rate, calculating cycle time, computing the minimum number of stations needed, assigning tasks to stations while ensuring the time at each station does not exceed the cycle time, and computing efficiency and idle time. An example of applying these steps to Vicki's Pizzeria is provided.

1. LINE BALANCING
Line Balancing is deciding the best physical arrangement of all
resources within a facility
Goal:
• Every one doing the same amount of work to customer
requirement.
• Variation is smoothed.
• No one overburdened ,No one waiting.
• Every one worked together in a balanced fashion.

2. PROCEDURES TO CALCULATE LAYOUT
Step 1: Identify tasks & immediate predecessors
Step 2: Determine output rate
Step 3: Determine cycle time
Step 4: Compute the theoretical minimum number of stations the Line)
Step 5: assign tasks to workstations (balance
Step 6: compute efficiency, idle time & balance delay

3. STEP 1: IDENTIFY TASKS & IMMEDIATE
PREDECESSORS
Vicki's Pizzeria and the Precedence Diagram
Immediate Task Time
Work Element Task Description Predecessor (seconds
A Roll dough None 50
B Place on cardboard backing A 5
C Sprinkle cheese B 25
D Spread Sauce C 15
E Add pepperoni D 12
F Add sausage D 10
G Add mushrooms D 15
H Shrinkwrap pizza E,F,G 18
I Pack in box H 15
Total task time 165

5. LAYOUT CALCULATIONS
• Step 2: determine output rate
• Vicki needs to produce 60 pizzas per hour
• Step 3: determine cycle time
• The amount of time each workstation is allowed to complete its task
 
 
sec./unit60
units/hr60
sec/min60min/hr x60
units/hroutputdesired
sec./daytimeavailable
)(sec./unittimeCycle 

6. LAYOUT CALCULATIONS CON’T
Step 4: compute the theoretical minimum number of stations
• TM = number of stations needed to achieve 100% efficiency (every
second is used)
• Always round up (no partial workstations)
 
stations3or2.75,
nsec/statio60
seconds165
timecycle
timestask
TM 


7. LAYOUT CALCULATIONS CONT.
Step 4: Assign task to work station
• Make sure the sum of task times at any station does not exceed the cycle time.
• There are rules that can be followed if there is a choice of task to assign to a station .
1.Number of follower rule
Select the task will have the most number of followers
2.Longest task time rule
Select the task with the longest task time.

8. Step 5: Assign tasks to workstations
Station Time Remaining Eligible Will fit Assign(Task
time)
Idle
1 60 A A A(50)
10 B B B(5)
5 C None None 5
2 60 C C C(25)
35 D D D(15)
20 E,F,G E,F,G G(15)
5 E,F None None 5
3 60 E,F E,F E(12)
48 F F F(10)
38 H H H(18)
20 I I I(15)
5 - - - 5

9. LAST LAYOUT CALCULATION
• Step 6: compute efficiency and balance delay
sec.100/60*sec.15timeidlePercent 
91.78.3%-100%Efficency 