I am looking for a line balancing simulation software (simple to use) to help me determine the number of resources required. Anyone can reconmend?

Hello Johnny !
Are you looking for something like this ?
http://www.promodel.com/
Plant, department, assy line, workcell ? What level ?
György

how is promodel compare to Simul8...which is easier to use?

anyone has excel spreadsheet that determine the number of operator required in a production line?

anyone has excel spreadsheet that determine the number of operator required in a production line?

I've attached a spreadsheet which will do as you ask based on your unique takt time. If you should be unable to balance the line, it will also show you the necessary buffers where necessary along with the amount required.

This is only my first draft which I did over the holidays and I'm in the process of expanding the file in my free time. There are comments in many of the fields which should help to explain the purpose.

You will need to enable macros in order to sort and calculate so don't be alarmed when the request appears when the file is opened. If it is disabled, the file will not perform the calculations correctly.

I hope it helps...any feedback would be appreciated as it is a work in progress.

Wayne

I received a question regarding the assignment of man to machines and thought I would provide the explanation I gave here as well.

The simple way to solve this is to determine your takt time and then divide this by the cycle time of the operation (takt/OPct= # operators). In this instance, it can a few different things:

1) The machine isn't fast enough, in which case I need to employ a second piece of equipment or run it on an additional shift.

2) If the machine is fast enough, but there are too many manual operations necessary, I can add additional help with one or more persons.

Having a time under takt could possibly mean that an operator may be able to operate an additional machine or take on additional tasks.

The spreadsheet I provided will perform this calculation, you would just need to act as if the assembly line consisted of only one station.

From a lean perspective, everything is driven by takt.

Wayne

I guess I should have share this...after all, this is what this site is...where we share experince and knowledge. Those in bold are replied by Wayne:)

We are working 12 hr per shift with total of 70 mins breaks (20 mins + 20 mins + 30 mins). I allocated 10 mins for team briefing and 10 mins for other allowances. So total allowances is 90 mins.

I am trying to fill-up the format. I am hiliting those that I don’t quiet understand.

Available time: 630 mins

Actually it would be (12hrs*60min)-70mins for breaks. You would also include any time allotted for meetings/training/etc.

This means that Station #1 needs to work extra to the daily production requirement. If the line is longer and the bottleneck is farther down

Current Standard = I do that by timing each station and add up the cycle time. Do I need to consider allowances?
If you are referring to PF&D, then yes, that needs to be included.

# of Operators = Is this the total number of current operators (not from calculation)

No. That's the current number of operators in your system, typically each station would have a single operator at a minimum.

Takt Time = I know how to calculate this.

Required Buffer Size = if Stn 1 is twice as fast as Stn 2….there will be 1 buffer at Station 2. Is that what this is showing?

If station #1 is faster than station #2, than no buffer is required between these stations. The buffer size is required when a station is slower than the "next" station.

Example: Station #1 is 1/2 the speed of station #2 and 100 are needed off the line each day. Station #1 would require that 50 pcs. be available after station #1 to allow Station #2 to meet the daily requirements.

If the line is longer, and the bottleneck farther in the process, than the necessary buffer would need to flow through all preceding stations. Hence the reason times would show up in all preceding stations even though no additional is kept there.

How do I modify the spreadsheet to have 20 stations?
That's going to require some work. You'd need to look at the data kept in the cells and copy/paste/modify as needed. The cells which would need to be modified are either in yellow or in the dark grey bordered area for the most part. There would also need to be some changes made in the "LookUp" worksheet, and to the macro used when the CALCULATION button is depressed.

Example: Station #1 is 1/2 the speed of station #2 and 100 are needed off the line each day. Station #1 would require that 50 pcs. be available after station #1 to allow Station #2 to meet the daily requirements.

I dont quiet understand the above. In pull system we were told there should not have buffer in between station. Somehow in real life there bound to have. The next question is what is the right buffer size.:confused:

Example: Station #1 is 1/2 the speed of station #2 and 100 are needed off the line each day. Station #1 would require that 50 pcs. be available after station #1 to allow Station #2 to meet the daily requirements.

I dont quiet understand the above. In pull system we were told there should not have buffer in between station. Somehow in real life there bound to have. The next question is what is the right buffer size.:confused:

Your exactly right, there should be no need for a buffer between operations. Unfortunately, it may take time or perhaps even an investment in equipment in order to achieve flow. A buffer is utilized until the problem can be eliminated.

The calculation for buffer size is taken from Demand Flow Technology and is:

Using any station or operation which has an operational cycle time below takt.
(("Time of Station Below Takt" - "Takt Time")*("Available Time" / "Time of Station Below Takt")) divided by TAKT. Round this up to the next whole number.

The goal of a buffer should be to assist in the creation of flow and not thought of as safety stock. While not the ideal scenario, it is a method to assist in meeting the customer's needs.

Wayne

To determine the number of operator, I use the folowwing formula.

no. of workstation = sum of task time divided by cycle time.

Does 1 workstation equal to 1 operator?

To determine the number of operator, I use the folowwing formula.

no. of workstation = sum of task time divided by cycle time.

Does 1 workstation equal to 1 operator?

I tried to keep the worksheet pretty general when I created it.

You can look at the sheet a couple of different ways:

I would assume there is one operator per workstation.

No of work stations and/or operators is equal to: Cycle Time / takt

The addition of extra people into a workstation would be for the purpose of balancing the process, and in order to achieve takt. Takt is key, that is the driver. If multiple are introduced into a workstation, you could apply the principle of "chasing the rabbit".

Something to remember is that this is just a tool, and more of a guide than an absolute. This worksheet gives you a starting place, not the destination. There still needs to be a certain amount of hands-on (i.e. go to Gemba) activity to reach the end product. The worksheet should take care of 80% of the trip.

Even for long-term planning purposes such as manning concerns, I always fall back on the use of takt. In fact, I just went through this exercise for all our assembly lines and if our yearly Forecast/Master Production Schedule hold true, :rolleyes: I know the manning requirements by month throughout the year.

Wayne

by cycle time do you mean the work time that should be spent on a workstation?

by cycle time do you mean the work time that should be spent on a workstation?

Yes. For a single workstation/operation it is that time, for multiple workstations/operations, it is the cumulative time.

Wayne

For simple machine to operator assigment problem, I use the following formula. correct me if I am wrong.

N=(L+P+U) / (L+U+W)

where
N = number of machine assign to an operator
P = time machine is running
L = time taken to load a workpiece
U = time taken to unload a workpiece
W = average time taken to walk to next machine

Hi,
here is linebalancing excel tool.
i used VBA forms for good user inerface
u can develop tools in vb.net or other languages with same logic.
if u have any problem
please let me know

ramesh Annabathula

Hi
Anne Marie from Ireland here. Just joined. Thanks for posting the excel sheet on takt time/line balancing. Just wondering if you revised it since.
All the best.:bigwave:

Can I have a simple line balancing MS Excel spreadsheet for manual Assembly operations ?

Hi Ajit,
I am looking for simple Line balancing software!!
Anne Marie

Ann Marie

Our company's product - Timer Pro Professional - has a module for line balancing by operators, production or takt time. We also have integrated video - so you can use the balance for operator training - and value stream mapping plus man machine charts.

You can find our product via google and the site also includes videos of the use of the line balancing features

As required by the terms of use this forum I have to tell you I am associated with this product and the company that developed it.

Hope this helps.

Doug Aird

Doug thanks for getting back to me on that. I will google it soon.
Anne Marie

I am looking for a line balancing simulation software (simple to use) to help me determine the number of resources required. Anyone can reconmend?


i am also search for it .can anyone introduce me any thig? spicially excel addins or sheet.

The attachment finds takt time and can help with line balancing. It is from another thread here but should help you.