ProBalanceManual_2F1EC6B40055E

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© 2011 Proplanner

ProBalance 2010

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ProBalance 2010I

© 2011 Proplanner

Table of Contents

ProBalance 2010 1................................................................................................................................... 2Installing ProBalance

.......................................................................................................................................................... 4System Requirements

................................................................................................................................... 5The User Interface

................................................................................................................................... 7ProBalance Menus

................................................................................................................................... 11Export to AutoCAD Tools

Data Editors 12

................................................................................................................................... 13Resource Editor

................................................................................................................................... 15Model Editor

................................................................................................................................... 17Parts Editor

................................................................................................................................... 20Station Editor

................................................................................................................................... 22Task Editor

.......................................................................................................................................................... 23Task Sheet

.......................................................................................................................................................... 26Precedence Graph

.......................................................................................................................................................... 30Task Grouping

.......................................................................................................................................................... 31Ergonomics

.......................................................................................................................................................... 35Consumption

Line Balancing 37

................................................................................................................................... 42Type I Balance

.......................................................................................................................................................... 45Monumental Resource Constraints

................................................................................................................................... 47Type II Balance

................................................................................................................................... 50Reassign Work

................................................................................................................................... 51Reports

Setting up a scenario 56

................................................................................................................................... 60Single-Model Balance

................................................................................................................................... 65Mixed-Model Balance

Single Model Tutorial 72

Mixed Model Tutorial 82

Manual Balance Tutorial 91

Multiple Operators Tutorial 95

Clusters and Lean Graph Tutorial 101



IIContents

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Station Compare Report Tutorial 108

Space Utilization Tutorial 115

Consumption Tutorial 120

Glossary 122



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1 ProBalance 2010

ProBalanceisaProplannerlinebalanceapplicationwhichallowsyoutocreatelinebalancing

scenarioswithyourcurrentprocessdata.Therearetwolinebalancingmethodsfeaturedinthe

ProBalancesoftware.Userscanchoosetoeitherminimizethenumberofworkstations(TypeI),

orminimizetheTakttimefortheoperations(TypeII).TypeIlinebalancingrequirestheusertospecifyaTakttimefromwhichtheprogramdeterminestheleastnumberofworkstationsneeded

fortheprocess.TypeIIlinebalancingrequirestheusertospecifythenumberofworkstations

desiredandbasedonthisinput,theminimumTakttimeiscalculated.IncludedwithProBalanceis

theoptiontolinebalanceforasingleormixedmodel,oneormultipleoperatorsinastation,and

foreitherasingleortwosidedproductionline.

TwosimpletasksarerequiredtocompletealinebalanceusingProBalance.First,usersneedto

inputtheirspecificprocessdata(example:ID,processtime,precedencerelationship).Afterthe

dataisintheprogram,thesecondtaskistocreatetheactuallinebalance(Manuallyor

ProBalanceGenerated)basedontheuserdefineddata.Detailsonhowtocompletethesetwo

tasksaredescribedinthesubsequentsectionsofthismanual.

LearnAboutLineBalancing

TermsandDefinitions

TheUserInterface

Creatingascenario

CalculationsandResults



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ProBalance 2010

1.1 Installing ProBalance

TouseProBalance,youhavethreedifferentoptions.Youwillseethescreensimilartotheone

beloweachtimeyouopenProBalance.

Activateonline

ToactivateandregisteryourcopyofProBalance,youmayselecttheonlineactivation

optionandyouwillseeawindowsimilartotheonebelow.EnteryourCompanyName,thenclick

theActivatebutton.TheProplannerlicensingserverwillbecontactedandavalidlicensewillbe

issuedimmediately.

Activatebyemail

ToactivateandregisteryourcopyofProBalancebyemail,youmayselectthisoptionand



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youwillseeawindowsimilartotheonebelow.FillinyourCompanyname,thenclicktheCopy

Infobutton.Thenclickonlicensing@proplanner.comtostartanemailmessageandpastetheinfo

intothemessage.AProplannerrepresentativewillrespondwithalicensefile.Onceitisreceived,

followthestepsbelow.

YouwillreceiveyourlicensefileasazippedemailattachmentfromProplanner.

Savetheemailattachmenttoyourcomputertothelocationwheretheapplicationisinstalled

(typically,C:\ProgramFiles\Proplanner\ProBalance).

Openthefile.Youcandothisbyeitherdoubleclickingandopeningthefileorbyextractingthe

informationinthefile.

ToExtracttheinformationfromthefile(rightclickonthezipfileandselect"ExtractAll").Thiswill

createanewunzippedfolder.

MovetheProBalance.Licensefiletothefolderwheretheapplicationisinstalled.

Startfreetrialusage

IfyouwouldliketotryProBalance,selectthisoptiontobegina30-daytrialperiodforfull-

featureevaluation.AstatusbarwillappearwhenyouopenProBalancetoindicatehowmanydays

remainonyourtriallicense.

IfyouhaveanyissuesorquestionsinregardstoobtainingalicenseforProBalance,please

contactlicensing@proplanner.com.TospeaktoaProplannerrepresentativedirectly,pleasecall

515-296-3236.

mailto:[email protected]

mailto:[email protected]



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ProBalance 2010

1.1.1 System Requirements

ProBalancerequiresMicrosoft.NETFramework3.5.Tostarttheinstallationexecute(doubleclick)

Setup.exefile.Iftherequired.NETversionisnotfoundonthemachine,thesetupwillautomatically

installit.



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1.2 The User Interface

ProBalanceprovidesuserswithanExcel-likeuserinterfacewhichmakesdataentryeasy.Users

canchoosetomanuallytypeinprocessinformationorcopyitfromanexternalsource.Thereare

twomainuserinterfacesusedinProBalance,theDataEditing (Figure1.2-1)andtheLine

Balancing(Figure1.2-2)interface.

DataEditing

DataEditingconsistsofTask,Station,Resource,Model,andPartseditors.IntheTaskEditor,

usersdefineprocessinformationsuchastheID,processtime,andtheprecedencediagram.All

model-relatedinformation,suchasdemandpercentages,isenteredintothe ModelEditor.Tools,

machinesandotherresourcescanbeenteredintotheResourceEditor,leavingallofthework

stationrelateddetailstobedefinedintheStationEditor.Theusercandefinethepartstobe

consumedinthePartsEditor.TolearnmoreaboutthedifferenteditorsprovidedinProBalance

eitherclickonthenameoftheeditororreferencetheDataEditingsectionofthismanual.

Figure1.2-1: Dataedit inguser interface

LineBalancing

TheLineBalancinginterfacedisplaysthelinebalancingoutputforthecreatedscenario.Depending

onwhethertheuserdesiresaTypeIoraTypeIIlinebalance,differentinformationisrequired.

Afterthebalance,linebalancingoutputs-generatedeithermanuallyorbyProBalance-are



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ProBalance 2010

displayedintheformofagraph.Theoutputcontainsusefulinformationabouttime,taskdetails,

andanyviolations(Resource,Precedence,etc.)perstation.Calculatedresultscanbeviewedand

printedfromtwoseparatereportslocatedinthispartofProBalance.

Figure1.2-2: Linebalancinguser interface



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1.3 ProBalance Menus

File

TheFilemenuoptionisvisibleforalllinebalancingtabsandviews.

1. NewScenario/OpenScenario/CloseScenario:Allowstheusertoopen,close,orcreatea

newscenario.

2. Save/SaveAs:Thisfeatureallowstheusertosaveanexistingscenario.TheSaveAsfeature

allowstheusertosaveanexistingscenariounderadifferentname.Thisisanimportantfeatureastheusercancreateseveraldifferentscenariosfromthesamelinebalancedata.

3. Print:TheprintoptionssuchasPageSetup,PrintPreview,andPrintarevisibleonlyforthe

BalancingStationView.

4. ExportFlowPlanner:Theexportto FlowPlannermenuallowstheusertosendupdated

locationinformationforpartsthathavebeenreassignedduetoarebalance.

5. Properties:Thepropertieswindowprovidesscenarioinformationsuchas,scenarioname,

createdby,createdon,lastmodifiedby,lastmodifiedon,lineside(SingleorMultiple), Work

Zone,timeunits,andadditionalcomments.



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ProBalance 2010

Edit

TheEditmenuisvisibleforalllinebalancingtabsandviews.

1. Find:TheFindfeatureenablestheusertosearchforanactivityinthetasklist.Theusercan

searchbyID,Name,TaskNo.,NetTimeandLineside.

Figure1.3-4: Findwindow

2. TaktTime:Thismenuoptionsisonlyactivatedinthebalancingstationview.Thisfeature

allowstheusertodrawadifferentTakttimelineonthegraph.



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3. Preferences:Thepreferencemenuletstheusermodifysettings.Youmay:

Setthegraphnodelegendfortheprecedencegraph.TheusercansetittoID,or

DESCRIPTION,orID:DESCRIPTION.

Setthedecimalprecisionfortimevalues.

Setthestartuppathtoanyfolderonthemachine.

SetuptheWorkZonesfortasksandstations.Separatethezonesbyacomma,fore.g.,a

stationcouldhavezoneslike,left,right,inside,outside,front,backetc.Typeinallthesein

theworkzonessection.Thesezonesarethenvisibletotheuserthroughdropdownlistsin

theTasksheetandthestationeditor.

4. ErgonomicsAttributes:Theergonomicsattributessheetallowstheusertoassociate

severalergonomicattributestoatask.TheusercancreatetheseattributesintheErgonomics

AttributesControl.

View

TheViewmenuisvisibleforalllinebalancingtabsandviews.Itallowstheusertoselectaneditor

orthebalancingstationview.



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ProBalance 2010

Balance

TheBalancemenuisvisibleonlyinthebalancingstationview.

Figure1.3-7: Balancemenu

1. AutoBalance: AllowstheusertoprovidethedesiredTakttimeordesirednumberofstations

forthelinebalance.2. ClearAllAssignments: Afterabalanceisgenerated,thetasksgetassignedtoawork

station.Clickingthismenuoptionremovesalltasksfromallstations.

3. RemoveEmptyStations: Allowstheusertoremoveemptystationsformthebalance.

Report

Thereportmenuisvisibleforalllinebalancingtabsandviews.

1. BalanceReport:Showsidletimeandutilizationofeachstation.

2. StationSummaryReport :Summarizesthetasksineachstation.Displaysthemodels,

timesandresourcesforthetasks.

3. ScenarioCompareReport:Thescenariocomparereportallowstheusertocomparetwo

linebalancescenarios.

4. ErgonomicsReport:Theergonomicsreportshowstheergonomicattributeofeachtaskby

station.



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1.4 Export to AutoCAD Tools

ThelinebalancedatacanbeexportedtotheAutoCADtools,WorkPlacePlannerandFlowPlanner.

ExporttoWorkPlacePlanner

Thelinebalanceroutineassignstaskstostations.Theworklocationdataforeachtaskindicateswhereinthestationthetaskisphysicallybeingperformed.Alongwiththeworklocation,theuser

willalsoprovidethedimensions/blockforthepartcontaineranddimensions/blockforthe

resource.AllofthisinformationcanbeexportedtoWorkPlacePlanner.Todothis:

Savethescenariofileafterthebalancehasbeencompleted.Makesurethatthetaskshave

worklocationsassigned.THEFILEISSAVEDASAN.XML.

OpenthescenariointheSequencetabofworkplaceplannerandprovideasequence.

ExporttoFlowPlanner

ThelinebalancedataforFlowPlannerismainlytiedtoparts.Asthelinebalancescenariois

modified,tasksgetassignedtodifferentstationsandasaresulttheconsumedpartsmoveaswell.TheFlowPlannerinputisalistoftheoldlocationsandnewlocationsofparts.Inordertoexport

thenewlocationstoFlowPlanner:

EnsurethateveryconsumedparthasCLOCandPLOC.TheCLOC(currentlocation)would

bethelocationthetaskhasmovedtoandthePLOC(previouslocation)wouldbethelocation

thetaskwasoriginallyassignedto.

ClickontheFilemenuandchoosetheExportFlowPlanneroption.

ProvideanamefortheoutputfileandclickOK. THEFILEISSAVEDASA.CSV.



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2.1 Resource Editor

Keepingtrackofavailableresourcesinaplantisveryimportant.ProBalanceaccountsforthis

importancebyallowinguserstomapresourcestoaspecifictaskand/orlocation.Actualtoolscan

bedefinedandthengroupedintouser-definedclasses.Userscaneithercreatenewresource

informationorcopyexistinginformationintotheresourceeditortomakedataentryquick.

LocatedintheResourceEditorarethefollowingfivecolumns:

1. ID:TheIDofaresourceisanuniqueidentifierthattheuserneedstodefine.TheIDcanbethe

actualassetnumberoftheresource,amake-orbrand-basedID,oranIDbasedonthelocation

ofthetool(e.g.ABC7862,Kraft001,Drill001orAssy001).

2. Type:ProBalanceallowsuserstodefineresourcesandresourceclassesintheresource

editor.Thetypeiseitheraresourceoraclass.ForexampleDrill001wouldbearesourceofthe

Drillclass.

3. Description: Adetaileddescriptionoftheresourceallowsuserstomorereadilyrecognizethe

resources.

4. Class:TheClasscolumnallowsuserstoassociatearesourcetoaspecificclass.Aclassisa

groupofresourcesthataregenerallysimilar(e.g.theclass"Wrench"maycontaintwelve

differentwrenches).Afterauserdefinesaclass,theclassIDwillappearinthisdropdownlist.

Theusercanthenassigntheappropriateclasstotheresourcebeingadded.

5. IsMonumental:The"IsMonumental"columnneedstobecheckedforresourcesthatare

fixedoraremonuments.Theseareresourcesthatcannotbemovedfromtheirpositionslikea

fixture,hoist,machine,etc.



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Data Editors

6.Width:ThisfieldistheactualWIDTHoftheresource.Incasetheresourcedoesnothavean

blockdefinedinAutoCAD,wewillusethiswidthtodrawanoutlineofthetool.Enterthewidthin

thesameunitsthattheAutoCADlayoutuses.UnitsarenotdefinedinProBalance,somaintain

consistencybetweenentriesinProBalanceandtheAutoCADlayout.

7. Depth:ThisfieldistheactualDEPTHoftheresource.Incasetheresourcedoesnothavean

blockdefinedinAutoCAD,wewillusethislengthtodrawanoutlineofthetool.Enterthedepth

inthesameunitsthattheAutoCADlayoutuses.UnitsarenotdefinedinProBalance,so

maintainconsistencybetweenentriesinProBalanceandtheAutoCADlayout.

8. BlockName:ThisistheblockthatwouldbeusedinAutoCADtodepictthisresource.Since

weexportthisdatatoAutoCAD,theblockwouldautomaticallybeusedinflowandworkplace

analysis.

9. LinesideWidth:Thisisthelinesidewidthrequiredbyatoolonthefloor(thefootprintofthe

tool).Thevalueenteredhereischeckedagainstthevalueenteredforavailablelinesidewidthat

astation,asistherequiredlinesidewidthforanypartsused.Inthisway,wecandeterminehow

muchoftheavailablespaceatastationisbeingusedandhowmuchspaceisavailable.The

unitsusedfortheLinesideWidthneedtobeconsistentacrossresources,parts,andstations,butthesearetheonlythreeareaswherethisinformationisused.Typically,userschooseto

entermeasurementsinmetersorfeet.ThisdataisalsoexportedtoWorkPlacePlannerand

FlowPlanner.



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2.2 Model Editor

ProBalancesupportsbothsingle-modelandmixed-modellinebalancing.Themodeleditorallows

youtodefinemodelsandoptionsalongwiththeirdemandpercentages.Boththe ModelSheet(

Figure2.2-1)andtheOptionSheet(Figure2.2-2)arelocatedinthemodeleditor.

ModelSheet

Figure2.2-1:ModelSheet

TheModelSheetcontainsthefollowingcolumns(Figure2.2-1):

1. ID:TheIDofthemodelbeingconsideredinthelinebalance.

2. Description: Adescriptionofthemodel.

3. DemandPercentage:Thedemandpercentageofamodelistheproportionoftotalproduction

thatthespecificmodelentails.Forexample,consideracompanywhichmanufactures100

vehiclesinamonth.Outofthe100vehicles,30areluxury,25aredeluxe,and45arestandard.

Basedonthisinformation,thedemandpercentageenteredintoProBalanceshouldbe.30for

luxury,.25fordeluxe,and.45forstandardvehicles.Foranygivenmodel,thecalculationis

DemandPercentage=(numberofSpecificModelitemsinorder)/(totalnumberofitemsin

order).ProBalanceusesthisinformationtocalculatethenettakerate(probabilityof

occurrence)oftheactivitiesmappedtothesemodeltypes.

OptionSheet



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Data Editors

Theoptionsheetallowsyoutolistalloptionalpartsandcomponentsavailableforamodel.

Figure2.2-2: OptionSheet

TheOptionSheetcontainsthefollowingcolumns(Figure2.2-2):

1. ID:TheIDoftheoptionsbeingconsideredinthelinebalance.

2. Description: Adescriptionoftheoption.

3. PenetrationPercentage:Thepenetrationpercentageistheprobabilityofoccurrencefora

specificoption.



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2.3 Parts Editor

ThePartsEditorcontainstwoworksheets:thepartssheetandthecontainerssheet.

PartsSheet

Thepartseditorallowstheusertoimportalistofpartsthatwillbeconsumedontheline.Thiswillhelptheuserafterthebalancebyprovidingalistofpartsneededateachstation.

Figure2.3-1:PartsSheet

PartID: ProvidetheIDofthepartbyeitherpastingitfromanexternalsourceorbytypingitin.

PartDescription: Provideapartdescription.

ContainerID:Thecontainerforthispart.ContainersarecreatedintheContainerstabofthe

PartsEditor.Aftercontainersarecreated,thecontainercanbeselectedfromadrop-downin

thecontainercolumnhere.

ContainerQty:Thisisthenumberofcontainersbeingmovedatonetime.

PartsPerContainer:Thestandardpacksizeofthispart.

LinesideWidth:Thisisthelinesidewidthrequiredbyapartonthefloor(thefootprintofthepart).Thevalueenteredhereischeckedagainstthevalueenteredforavailablelinesidewidth

atastation,asistherequiredlinesidewidthforanytoolsused.Inthisway,wecandetermine

howmuchoftheavailablespaceatastationisbeingusedandhowmuchspaceisavailable.

TheunitsusedfortheLinesideWidthneedtobeconsistentacrossresources,parts,and

stations,butthesearetheonlythreeareaswherethisinformationisused.Typically,users

choosetoentermeasurementsinmetersorfeet.ThisdataisalsoexportedtoWorkPlace

PlannerandFlowPlanner.



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Data Editors

ContainersSheet

Figure2.3-2:ContainerSheet

Thecontainerssheetlistsallthepartcontainers.Thefollowingfieldsarerequired-

ID: Auniqueidentifierforeachcontainer.

Description: Thisisthedescriptionofthecontainer.Width:ThisfieldistheactualWIDTHofthecontainer.Incasethecontainerdoesnothavean

blockdefinedinAutoCAD,wewillusethiswidthtodrawanoutlineofthecontainer.Enterthe

widthinthesameunitsthattheAutoCADlayoutuses.UnitsarenotdefinedinProBalance,so

maintainconsistencybetweenentriesinProBalanceandtheAutoCADlayout.

Depth:ThisfieldistheactualDEPTHofthecontainer.Incasethecontainerdoesnothave

anblockdefinedinAutoCAD,wewillusethiswidthtodrawanoutlineofthecontainer. Enter

thedepthinthesameunitsthattheAutoCADlayoutuses.Unitsarenotdefinedin

ProBalance,somaintainconsistencybetweenentriesinProBalanceandtheAutoCADlayout.

BlockName:ThiswouldbetheblockinAutoCADthatisusedtodepictthiscontainer.Since

weexportthisdatatoAutoCAD,theblockwouldautomaticallybeusedinflowandworkplaceanalysis.

Theadvantageofenteringallthepartsdataandassociatingitwithtasksisthataftercompletinga

linebalance,alistofpartsforeachtaskatastationisprovided.



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Figure2.3-3:LineBalanceSnapshot-Partsare l istedwithtasks



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Data Editors

2.4 Station Editor

ThecurrentworkstationsassignedtoaproductionlinecanbedefinedintheStationEditor.This

providestheoptiontoenterinformationaboutaspecificworkstation,suchaswhetheritisleft-or

right-lineside,whichresourcesareavailable,andthenumberofoperatorsatthestation.

Figure2.4-1:Stat ionEditor

TheStationEditorcontainsthefollowingsevencolumns:

1. ID: TheIDisauniqueidentifieroftheworkstation.TheIDcanbebasedonacertain

productionline,thenearestcolumninthelayout,orontheassemblybeingcreated--thestation

namingtechniqueisuptotheuser.

2. Description: Abriefdescriptionofthestation.

3. Order:Thestationordercolumnindicatestheorderinwhichstationsappearonthe

productionline.Forexample,thefirststationonalineisgivenanordernumberof1andthe

fifthstationisgivenanordernumberof5.

4. Resources: Aresource(tool)canbeassociatedwithaspecificstationinthiscolumn.This

isacriticalstep,sincethelinebalancingoperationwillflaganyresourceviolationsbasedon

whattheuserentershere.Ifaresourcerequiredbyataskisnotmappedtothestationthe

taskisassignedto,aflagwillnotifytheuser.Theresourcecolumncontainsadroplistwithall

ofthetoolsandresourceseligibletothatstation.Userscanthenselecttheresourcefromthe

list.Alloftheresourcesandtoolsavailableinthiscolumnwereenteredinthe ResourceEditor

.

5. Zones:Astationcouldhavemultiplezones,indicatingthattheoperatorcanworkindifferent

areasoftheworkstation.Inordertoaddzones,createacommaseparatedlistofthe



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applicablezonesandmapthemtoastation.Note:Thezoneshereshouldmatchthelistof

zonesinthePreferencesmenu.

6. OperatorCount: Enterthenumberofoperatorsperstationintheoperatorcolumn.Each

stationcanhaveoneormoreoperators.Theamountofworkallottedtoastationwilldepend

onthenumberofoperators.

7. AvailableW idth:Thisisthelinesidewidthavailableatastation(thefootprintofthetool).The

valueenteredhereisusedtocheckhowmuchavailablespaceistakenupbytheresources

andpartsassignedtothestation.Wecandeterminehowmuchoftheavailablespaceata

stationisbeingusedandhowmuchspaceisstillavailable.TheunitsusedfortheLineside

WidthorAvailableWidthneedtobeconsistentacrossresources,parts,andstations,but

thesearetheonlythreeareaswherethisinformationisused.Typically,userschoosetoenter

measurementsinmetersorfeet.ThisdataisalsoexportedtoWorkPlacePlannerandFlow

Planner.



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Data Editors

2.5 Task Editor

Thetaskeditorallowsyoutoenterdataonprocesses(alsocalledtasksoractivities).Eachrowin

thetaskeditor'sTaskSheetisanactivity(ortask)andeverytaskenteredmusthaveanIDanda

ProcessTime.Theothercolumnsareforadditionalinformationthattheusercanaddifdesired.

InadditiontotheTaskSheet,therearetwoothertabpageswithintaskeditor.Eachofthese

allowsyoutospecifyevenmoreinformationaboutyourprocess.Onepagecontainsauser-

definedPrecedenceGraphandtheotherprovidestheoptiontogrouptaskstogether(Task

Grouping).Alloperationsthatwillbeincludedinthelinebalancemustbeenteredintothetask

sheetandalsohavetheprecedencespecifiedinthePrecedenceGraph.Figure2.5-1 showsthe

taskeditorwiththeTaskSheetopen.Theothertabsareavailableatthebottomofthetasksheet.

Figure2.5-1:TaskEditorwithTaskSheetdisplayed

1. FileOpen/Close/SaveandFind

2. TaskSheet

3. PrecedenceGraph

4. TaskGrouping



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2.5.1 Task Sheet

Thetasksheetiswhereyoucanentertaskrelateddetailsandmapmodel,option,andresource

data.Clickingthetagonthecolumnheadinggivestheoptiontofilterthetaskdataaccordingto

uniqueitemsinthatcolumn.Thefieldsdescribedbelowwitha(WPP )designation,indicatethat

thosedatafieldsaresavedfromProBalanceandtransferredtothe ProplannerWorkplacePlanner

application.

TheTaskSheetcontainsthefollowingeighteencolumns:

1. ID:TheIDofataskisauniqueidentifier.TheIDcanbeassimpleas1,2,3orcouldbebased

onthemanufacturingprocess(Assembly01orInspect01),linelocationorworkstation(Stn603-

01),orbytheproductbeingmanufactured(Chassis01).Thenumberingschemeisuptothe

user.

2. Description: Thedescriptioncolumnallowsuserstoenterinformationtoidentifythetask.

3. Type(WPP): Theprocesstypecolumnhelpsidentifyvalue-addedornon-valueaddedtasks.A

"M"typeimpliesitisamanualprocess,a"W"typeimpliesitisawalkprocessandan"I"type

impliesitisacombinationofwalkandamanualprocess.Typicallyawalkprocessis0%valueaddedandamanualprocessis100%valueadded.

4. Time(WPP):Therearethreetypesoftimesbeingtrackedwithinthetool.ProcessTime,Walk

TimeandMachineTime.Iftheuserhasonlyonetimeforthetask,thattimeshouldbeenteredin

theProcessTimecolumn.

ProcessTime:Theprocesstimeisthetimevalue-addedworkisdone.

WalkTime:Thewalktimeisthetimespentdoingnon-value-addedwork(e.g.walking).This

fieldisrequiredifusingProBalanceinconjunctionwithWPP.

MachineTime:Themachinetimeisthetimeinvolvedindoingnon-value-addedwork(e.g.the

userwaitingonamachinecycle).ThisfieldisrequiredifusingProBalanceinconjunctionwith

WPP.5. Freq.:Thefrequencyoftheactivitywithintheprocessplan.Bydefault,thefrequencyissetto

one.

6.Occ.:Howmanytimestheactivityoccurs.Bydefaulttheoccurrenceissetatone.

7. NetTime:Thenettimeoftheactivityiscomputedas:

[(Processtime+Machinetime)*Frequency+WalkTime]*Occurrence

Thenettimecomputationcanbestbeexplainedthroughanexample.Supposethereisaprocess

whichrequirestighteningfourbolts.Tighteningoneboltconsumesonesecond.Aftertwoboltsare

tightened,theoperatorwalkstoabinandpicksuptwomoreboltsandthenreturnsandfinishes

theassembly.Aonewaytriptotheboltbintakestwoseconds.Forthisscenario,theprocess

timeisonesecond,andthewalktimeisfourseconds(roundtrip),percycle.Frequencyforthe

bolttighteningprocessisfour,sincetheoperatoristighteningfourboltspercycle.Thenettimefor

thisoperationiscalculatedbelow.

[(1+0)*4+4]*1=8seconds

Thisentiresetcouldhappenforeveryassemblycomingdowntheline(asisthecaseabove).The

occurrenceinsuchacaseis1,orforaspecificsetofassemblies(say1inevery4),the

occurrencewouldthenbe0.25.

http://www.proplanner.com/Product/Details/WorkplacePlanner.aspx



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Data Editors

8. VA%(WPP):Valueaddedpercentageisauserinput.Theusercanprovideapercentagebased

onthevalueaddedcontentofthetask.

9. NVA%(WPP):Non-value-addedpercentageisauserinput.Theusercanprovidea

percentagebasedonthenon-valueaddedcontentofthetask.10.NVBN%(WPP):Non-value-added-but-necessarypercentageisauserinput.Theusercan

provideapercentagebasedonthenon-valueaddedbutnecessarycontentofthetask. Note:

ProBalancedoesnotautomaticallycalculatethevalue-addedornon-value-addedcontentofthe

task.Itispurelyauserinput.

11.Models:ProBalancehandlesbothsingle-andmixed-modelprocesses.Withasinglemodel,

theuserdoesnotneedtospecifywhichmodelisbeingbalancedandcanleavethiscolumn

blank.Inthecaseofmixedmodels,theusercanselectanymodelwhichhasalreadybeen

definedintheModelEditor.Ataskismappedtoanymodelwhichisselectedortypedintothe

modelcolumn.Ifthetaskisnecessaryformultiplemodels,usersmustseparateeachmodel

namewithacomma.

12.NetTakeRate:Thenettakerateistheprobabilityofoccurrenceforaspecifictask.Itsvalue

isdependantonboththedemandpercentageforthemodelsandthepenetrationpercentagefortheoptionsthataremappedtothetask.Forexample,consideraprocessformanufacturing

threeautomobilemodels(standard,deluxe,andluxury).Thedemandpercentageforthethree

modelsis0.45,0.25,and0.30respectively.Taskswhichareonlyapplicabletoa“standard”

modelwouldhaveanettakerateof0.45.Ataskwhichisusedfor"standard"and"deluxe"would

haveanettakerateof0.70(=0.45+0.25).Finallyifthetaskisusedforallthreemodels,thenet

takeratewouldbe1.00(=0.45+0.25+0.30).

13.Resources:Thetoolsandmachinesrequiredbythetasksarelistedintheresourcecolumn.

TheuserneedstofirstdefineallresourcesintheResourceEditor.Mappingaresourcetoa

taskprovidesinformationtoProBalancetoflagtheuserifthereisamissingresourceafterthe

linebalanceforthetaskshasbeengenerated.

14.Station:ProBalancecomputesthestationassignmentautomatically.Oncethelinebalancehasbeenperformed,theassignedstationIDappearsinthestationcolumn.Allstationsthat

currentlyexistonaproductionlinecanbedefinedintheStationEditor.

15.WorkLocation(WPP): Theworklocationiswheretheworkisphysicallybeingdonewithina

station.Thisisaspecificlocationwithinastation.ThisisaWPPinput,sothosejustdoinga

linebalancecanleavethiscolumnblank.

16.Remarks:Theremarkscolumnisaplacefortheusertoaddadditionalcommentsaboutthe

task.

17.ElementData(WPP):Pre-determinedtimecodes(MODAPTS,MTM-1,MMMMetc.)forthe

activityshouldbeprovidedintheelementdatacolumn.ThisagainisaWPPinput.

18.Zone:Eachstationcanhavemultipleworkzonesinit.Theusercandefinethesezonesandthenmapthemtothetask.ProBalancelooksatthezonerequirementofthetaskandassigns

taskstostationsthathavethecorrespondingzones.Forinstance,StationOnecouldhave

threezones,L(Left),R(Right),A(Above),andStationTwohasonlyonezoneU(Under).Any

underbodytaskswouldbeassignedtoStationTwo,andnotasksrequiringL,RorAwouldbe

assignedtoStationTwo.RefertothedocumentationinMenusfor Addingzones.

ModifytheconfigfilebyaddingvaluestothekeycalledWorkZone.Fore.g.intheimagebelow,

Front,Back,Topetc.arenewzonesaddedtotheapplication.TheusercanthenaddontheZone



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columnandmapthezonetothetask.

Figure2.5-2: Mappingzonestoatask



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Data Editors

2.5.2 Precedence Graph

TheprecedencegraphisthemostimportantpartofProBalance.Thegraph( Figure2.5-3)

depictstheorderinwhichtheactivities(tasks)musttobedone.Taskassignmentsaremade

basedontheprecedence;notaskswillbeassignedinanorderthatviolatesprecedence.

Figure2.5-3:PrecedenceGraphUserInterface

HighlightsofFigure1:

1. ZoomControls

2. DefaultAssignment

3. AutoArrange

4. PrecedenceGraph5. TextEditor

6. ClusterList

7. ViewType

Basedonthetaskslistedinthetasksheet,correspondingnumberofnodes(yellowcircles)

willbedrawnintheprecedencegraph.Theusermustdrawarcsbetweenthenodestodepict

theorderinwhichthetasksshouldbedone.Thearcscanbecreatedintwoways.First,they



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canbedrawnonthegraphitself.Second,aworksheetisprovidedthatallowstheuserto

typeinthecorrectpredecessorsforeachtask,whichalsogeneratestheappropriatearcs.

Clickingthedefaulticon(2)willalignalltasksinonestraightline,indicatingthatthetasksare

tobedoneoneaftertheother.Theautoarrangeicon(3)re-drawsthegraphinanorganized

manner.TaskID's,TaskDescriptionsorTaskID's&DescriptionscanbedisplayedontheTask

nodeswithinthePrecedencegraph.TheseTaskDisplaysettingscanbechangedfromthe

PrecedenceoptionontheEditmenuinthetopleftcornerofProBalance.

EditingtheTasks

Asmentionedabove,thePrecedencegraphcanbeeditedintwoways:

1. Editingwiththegraph: Theuserhastodrawarcsbetweenthenodestodepicttheorderin

whichthetasksshouldbedone.Todrawanarc,movethecursortothecenterofthenode.

Thecursorwillappearasahandicon.Thenclickonthecenteranddragthecursortothenode

towhichthearchastobedrawn.Releasethemousebutton.Thearcwillbedrawn.

2. Usingthetexteditortoedit:Eachtaskintheprecedencegraphhasatasknumberassigned

toit.Inordertodefinethegraphwithtext,theuserneedstoprovidetasknumbersofthe

precedingtask(s).Noteintheimagebelow,MetalCuttingandWeldingaredonebeforethe

HolePunchtask,makingbothtask3andtask2predecessorsoftask4.

Figure2.5-4: Precedencegraphexample

Figure2.5-5: Correspondingentry intexteditor



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Data Editors

EditingtheClusters

Clustersareaconceptimplementedtosimplifyprecedencegraphs.Insteadofseeingallthe

individualtasksinoneview,theusercanspecifyclusterstoassigngroupsoftasksto.For

example,anautomotivemanufacturermaywanttoassignallengine-relatedtaskstoacluster,and

allframe-buildingtaskstoanother.Inthisway,theusercanworkthrougheditingtasksineach

clusterwithoutworryingaboutalloftheothertasksintheprocess,andthenmoveontothenext

cluster.Aprecedencebetweentheclusterscanbedefinedaswell.

1. Inordertocreateacluster,changetheviewtypetoCluster.

2. Theuserwillseeadefaultclusterpresent.Inordertoaddnewclusters,typetheclusternamein

theclustercolumn.

3. Oncetheclustershavebeencreated,savethelist.

4. Atthisstage,theusercandefineaprecedencerelationshipamongtheclusters(therelationship

ofthetasksinsideoftheclusterswillbedefinedlater).

5. Next,changetheviewtypetoTaskGraph.



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6. Nexttoeachtaskinthelistbelow,theusercannowprovidetheclusterthistaskbelongsto.

7. Oncethetaskshavebeenassignedacluster,theuserwillnowseealltheclusterslistedinthe

Clusterdrop-down(locatednexttotheViewType).Selectaclustertoseethetasksthatare

assignedtothatcluster.

8. Tocreateprecedencefortaskswithinaspecificcluster,selectaclustertobeeditedfromthe

list.Thecorrespondingtasksappearinthespreadsheetandinthedrawing.Youmayeither

drawlinesordefineprecedencebyprovidingtheTaskNoofthepredecessor.



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Data Editors

2.5.3 Task Grouping

Thetaskgroupingfeature(Figure2.5-8)inProBalanceallowsyoutogrouptaskstogether.This

isanimportantfeaturefortasksthatalwaysneedtobedonetogetheratonelocation.Tocreatea

group,selectallthetasksthatwillbeinthegroup,rightclickandselectaddtogroup.Userscan

addthetaskstoanexistinggrouporcancreateanewgroup.

Note:Oncetheactivitiesaregrouped,theywillactasoneblockorsetoftasks.DefiningaTakt

timelessthanthetotaltimeofthegroupwillresultinanerror.Theuserwillbeaskedtodefinea

timegreaterthanthetotaltimeofthegroup.

Figure2.5-8: TaskGrouping interface



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2.5.4 Ergonomics

Theergonomicssheetallowstheusertoassociateseveralergonomicattributestoatask.The

usercancreatetheseattributesintheErgonomicsAttributesControl.

TheergonomicssysteminProBalanceworksinthefollowingmanner-

1. Theuserfirstdefinesattributesorbodymovementsforthestudy.

2. Nexttheusersetsamin,maxandthresholdvaluesforeachattribute.Theuseralsodefinesthe

formulatobeusedtocomputethesummaryoftheattributeateachstation.Thesummary

formulaisuser-defined.Forexample,thesummarycouldbesumofalltheattributevaluesata

station.

3. Thethresholdvalueisthehighestpossiblesummaryvalue.Anyattributethatcrossesthe

thresholdishighlightedtotheuser.

4. Foreachtasktheusermapsergonomicattributesandputsinavalueforeach.

5. Theuserbalancesthelineandassessestheergonomicratingofeachstation.

DefiningAttributes1. OpentheErgonomicsAttributesEditorundertheEditMenu.

2. Eachrowinthiseditorcorrespondstoanergonomicattribute.Thesystemhasafewdefault

attributespre-defined(Hand,Shoulder,Elbowetc.).

3. Eachergonomicattributehasthefollowingproperties

Wewilluseanexampletobestexplaintheseproperties.Saytheshoulderattributecanhavea

lowestvaluesof0andahighestvalueof10(0beinglowstressand10beinghighstress).The

thresholdvalueis30,thisimpliesthatthesumoraverage(oranyotherfunctiontheusermaywish

touse)oftheshoulderattributesofallthetasksinastationcannotexceed30.



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Data Editors

Name:ThisisthenameoftheattributethatisusedbyProBalance. Note:Thenameofthe

attributeshouldcontainonlyalpha-numericcharacters.Thereshouldalsonotbeanyspaces

inthename(e.g.SHOULDER).

DisplayName:Thedisplaynamewillbethenameofthecolumnthatisdisplayedinthe

Ergonomicseditor.Description:Typically,thesameasthenamebutwithmoredetails.Thisisanoptionalstep,

andthedescriptioncolumncanbeleftblank.

MinRangeValue: Thisisthelowestallowedvalueoftheattribute(e.g.0)

MaxRangeValue:Thisisthehighestallowedvalueoftheattribute(e.g.10).

ThresholdValue: Thehighestallowedsummaryvalueforanattributeacrossalltasksina

station(e.g.30).

FlagIfSummaryValue<ThresholdValue?: Bydefault,thesystemwillchecktoseeif

thesummaryvalueofaattributeisgreaterthanthethreshold.Thisflagshouldbesetifthe

userwantsthesystemtocheckintheoppositedirection.i.e.toseeifthesummaryisless

thanthethreshold.

IsDerivedColumn: Aderivedcolumnisonewhichcontainsacertainformula.Thiscolumn

allowstheusertouseexistingcolumnstocomputevalues.

-Thisisanoneditablecolumn(readonly),thevalueinthiscolumniscomputedfromother

columns.

-AderivedcolumnwillnothaveaMinorMaxvalue.

Atanytimeofdefiningattributestheusercaninsertaderivedcolumn.Thiscolumncan

containaformulatiedtotheNetTime,WeightedTimeoranyotherattributecolumn.Theuser

caninsertaSum,Average,Max,Min,StandardDeviationformulainhere.Iftheuserwantsto

usemorethanacell,theformatshouldbeFUNCTION([#ColumnName],[#ColumnName]).

Fore.g.

DisplaytheNetTime-"#NetTime"

DisplaythesumofAttr001andAttr002-IsDerivedColumn="SUM([#Attr001],[#Attr002])"

Displaythemaximumofthetwocolumns-IsDerivedColumn="Max([#Attr001],[#Attr002])"

TheusercanusestandardMSEXCELfunctionsinthiscolumn.

SummaryFormula:Thesummaryformulaisusedinthelinebalancescenario.Thesummary

valuesarecomputedforeachattributeinastation.Thenthethresholdvalueiscomparedto

thevalueinthesummarycolumn,whichisalsoaformulacolumn.Theformuladefinedhere

isrestrictedtofunctionsthatworkoverarangeofvalues,suchasMAX,MIN,SUM,

AVERAGE,PRODUCTetc.Thesummaryvalueiscomparedtothethresholdvalue,andtheresultingcelliseithergreenorreddependingonthecomparisonresult.Theusercanuse

standardMicrosoftExcelfunctionsinthiscolumn,butagain,onlythosethatworkforarange

ofvalues.

MappingValuestoTasks

1. InthetasksheetclickontheErgonomicstab.BydefaulttheNetTimeandWeightedTime

columnsarealwaysvisible.Anyothercolumnisanattribute.



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2. Thenassignattributevaluesforeachtask. Note:thevaluesmustbewithinthemaxandmin

rangefromtheattributeeditor.Theuserisnotallowedtotypeinavalueoutofthespecified

range.3. Thethirdstepistoassignvaluestoeachattribute.Oncethevaluesareassignedtheresultscan

beseenintheErgonomicstaboftheLineBalancingView.



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Data Editors

Notes:

Inthesituationshownabove,StationBB001hastwooperatorsandanergoassessmentisavailableforeach.

Inordertomovetasksbetweenoperators,theuserhastobeintheStationView.



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2.5.5 Consumption

Theconsumptionsheetallowstheusertoassociatepartstoprocesses.Thepartshavebeen

definedinthePartsEditorandtheprocesseshavebeencreatedintheTaskSheet.Itisatthe

consumptionscreenthetwocometogether.

ThecolumnsintheconsumptiontaboftheTaskEditorinclude:

TaskNo:Thetasknumberfromthetasksheet.

TaskID:ThetaskIDfromthetasksheet.

TaskDescription:Thetaskdescriptionfromthetasksheet.

Models:Showsthemodelsmappedtothetask.

Options:Showstheoptionsassociatedtothetask.

Station:Showsthestationthatismappedtothetask.

PartID:Heretheuserwillselectthepartthatwillbeconsumedbytheprocess.Incases

wherethetaskconsumesmorethanonepart,rightclickonthepartIDandselecttheInsert

menuoption.ThiswillinsertasecondrowinthepartIDcolumnandtheusercannowselect

anotherpart.



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Data Editors

PartDescription:Showsthedescriptionofthepart(updatedautomaticallyaftersaving).

Quantity:Allowstheusertospecifythequantitybeingconsumed.

CLoc:Thisisthecurrentlocationofthepart.Fortaskswhichhavebeenmovedtonew

WorkStations,theCLocwillbetransferredtothePLocfieldandtheCLocfieldwillberesetto

blank.

PLoc:ThePLocisthepreviouslocation.Whenataskisassignedtoadifferentstation,the

oldlocationofthetaskwillbecomethePLocandthenewlocationwillbetheCLoc.

NOTE:THECLOCANDTHEPLOCAREBASEDONAUSERINPUT.WEDONOT

STOREPARTLOCATIONSASAPARTOFTHESCENARIO.



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3 Line Balancing

Onceallofthenecessarydatahasbeenenteredinthedataeditors,thescenarioissetupanda

linebalancecanbegenerated.Togotothebalancingstationview,clickontheViewmenuand

select'BalancingStationView'.

BalancingStationView

Thebalancingstationview(Figure3-1)istheresultssectionofProBalance.Inthisview,thereare

twomainareas,thelinebalancegraphandthetasklistforeachstation.Thelinebalancegraphin

turnhastwoviews,thestationviewandthevalueaddedview.

Figure3-1:ResultswindowinProBalance

ThefollowingfeaturesareavailableintheBalancingStationView:

1. FileOpen/Close/SaveandFind.2. AutoBalance3. UnassignedProcesses4. LineBalanceGraphView5. ModelLegend6. StationSelection



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Line Balancing

7. TaskDetails8. TaskViolations9. CollapsibleViews10.OperatorView11.GraphViews

Aselectionofthesefeaturesaredescribedinmoredetailbelow.

FileOpen/Close/SaveandFind: Allowsuserstoopenorsaveanexistingfile.TheFindfeature

enablestheusertosearchforanactivityinthetasklist( Figure3-2).TheusercansearchbyID,

Name,TaskNo.,NetTimeandLineside.

Figure3-2: Findcontrol

AutoBalance: TheautobalancebuttonallowstheusertoprovideaTakttimeornumberof

stationsdependingonthetypeoflinebalancedesired(Figure3-3).

Figure3-3: Autobalancecontrol

Therearethreestepsinvolvedinachievinglinebalanceresults:

SelectingtheBalanceType:MinimizingnumberofstationsorminimizingtheTakt

time

SelectingtheBalanceAlgorithm:WeightedAverageBalance(Default)orPeakModel

Balance

ProvidingUserInput:SpecifyingtheTakttimeorenteringthenumberofstations

UnassignedProcess:Thetasksthatarenotassignedtoastationgetplacedintheunassigned



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list.Beforebalancingtheline,bydefaultalltaskswillappearintheunassignedlist.

StationSelection:Thelistofstationsthatexistwillappearhere.Theusercanselectastation

hereordoubleclickonthegraphtoviewthetasksforthatstation.

TaskDetails:Thetasklistbelowthegraphprovidesthefollowingdetails:

· ID:ProvidestheIDofthetask· Description:ProvidestheDescriptionofthetask

· NetTime:Providestheactualtimeofthetask

· WeightedTime:Providestheweightedtimeofthetask(timewiththemodelandoption

takerateapplied)

· Violations:Providesanyresource,precedence,ormonumentalresourceviolations

· Models:Providesthelistofmodelsmappedtotheactivity

· Options:Providesthelistofoptionsmappedtotheactivity

· Resources:Providesalistofresourcesconsumedbytheactivity

· LineSide:Providesthelinesideoftheactivity

AswiththecolumnsintheTaskEditor,clickingonthetaginthecolumnheadingallowstheuserto

filterthetaskdataaccordingtotheuniqueitemsinthatcolumn.

LeanGraph(Checkthe'ShowVA/NVAChart'box)

Theleangraphallowstheusertovisualizethevalueaddedpercentagesateachstation.Inorderto

doso,thevalue-added,non-value-addedandnon-value-added-but-necessarypercentagesfor

eachtaskmustbeentered.Thegraphrollsupthesevaluesforeachstation,creatingachart

similartotheonebelow.



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SpaceUtilizationView(Gotothe'SpaceUtilizationView'tab)Thespaceutilizationviewshowsamountofspacebeingutilizedateachstation.Theavailable

spaceisbasedonthe'AvailableWidth'atastation.Thespaceconsumedbypartsandresources

isbasedontheLinesideWidthofthecontainersandtools.



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3.1 Type I Balance

MinimizingthenumberofstationsisreferredtoasaTypeIbalance.Thistypeofbalancerequires

theusertospecifyaTakttimebeforeProBalanceassignstaskstostations.Inthissituation,

ProBalancetriestominimizethenumberofstationsrequiredtocompletethelistoftasksatthe

givenTakttime,whileensuringthattheprecedencerelationshipismaintained.

StepstocreateaTypeILineBalance

1. Afterdefiningtask,resource,andmodelinformation,savethescenarioandclickonthe

"BalancingStationView"undertheViewoption.Acellphoneexamplescenarioisprovidedinthis

manualandwillbereferencedinthisTypeIlinebalancesection.Toloadthisscenariodataclick

on“File>OpenScenario”andthenclickCellphone.xml.

2.NextgototheBalanceStationViewandclickonthe"AutoBalance"iconinthemenubar.

3. Theautobalanceoptionscreenwillappear.Selectthebalancetypeas"Minimizenumberof

stations"andselectWeightedAverageBalance.

4. NextprovidethedesiredTakttimeandclickOK.Ifyouarefollowingalongusingthecellphone

scenario,typein20asthedesiredTakttime.

Figure3.1-2: Autobalancescreen

5. ThelinebalancegraphbelowshowsthatfivestationswereneededfortheTakttimeof20for

thecellphoneexample.Belowthefigureisalistofdetailstonoticeinthelinebalancethatwas

generated.



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a.Station1containsonlytwotasks,T01andT02.Ifthenexttaskintheprecedence

graphwasaddedtothisstation,itwouldexceedtheuser-definedTakttime.Alsonote

thatthereisnoresourceviolationinthisstation.Fixture01wasrequiredfortaskT01and

ispresentatstationST01.

b.Station2containsanoption-relatedactivityT04formodelsM03andM04.Notehow

thegraphdisplaysalargertimeforbothofthesemodelsduetotheextraactivityrequired.

Itisalsoimportanttonoticetheresourceviolation,whichisduetotheabsenceofthe

requiredsolderinggun.

c. Station3containsamonumentalresourceviolation.Fixture02isnotavailableatstation

ST03.Tocorrectthisproblem,theusercanrebalancetheline--andthistimecheckthe

monumentalresourcebox.Checkingthe'ConsiderMonumentalResourceConstraints'

ensuresthatnomonumentalresourceviolationsoccurinthelinebalance.Toseethisinthecellphoneexample,clickonthefollowinglink: monumentalresources

d.Station4hastimesexceedingTakttimeformodelsM02andM04.However,thisisnot

aproblemsincetheaveragetimeisstillbelowthespecifiedTakttime.Thisisthe

advantageofusingtheweightedaveragealgorithm;eventhoughafewmodelsexceed

Takttime,thestationonaverageisbelowTakt.

6.Nextbalancethelineagain,butthistimeselectthepeakmodelbalancealgorithm.Again,use20



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Line Balancing

astheTakttimevalue.

7. Thelinebalancegraphshowsthat5stationswereneededinthisbalancealso.Afterthefigure

belowisalistofdetailstonoticeinthepeakmodelbalanceoutput.

a. ThetaskassignmentsforstationST01,ST02andST03areidenticaltothoseinthe

weightedaveragebalance.

b. Station4doesnotcontainasmanytasksasitdidintheweightedaveragebalance.This

isbecausethepeakmodellogicdoesnotallowanyofmodelstocontainanytasksthat

causeittoexceedTakttimewithinastation.Theweightedaveragelogic,ontheother

hand,considersitacceptabletoexceedTaktforsomemodelsaslongastheaverage

timeforthestationisbelowTakttime.Inthepeakmodelcaseforthecellphones,task

T11(attachingantenna)wasmovedtostationST05.

8.Usershavetheoptiontoreassignworkafterthelinebalancehasbeengenerated.Reference

theReassignWorksectionofthismanualformoredetails.



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3.1.1 Monumental Resource Constraints

1. FromtheTypeIbalancetheusercanseethatstationST03hasamonumentalresource

violation(taskT06).AresourceFixture02isnotavailableatthestation.Fixture02hasbeen

definedasamonumentalresource,whichimpliesthatitcannotbemovedfromitsassigned

station.

2. Theusercannowassigntheresourcetoanystation.Forthisexample,Fixture02isassignedto

stationST04.InordertodotheassigntheFixture02toST04,clickonview>stationeditor.

ThenclickontheresourcecolumnforstationST04andselecttheresourceFixture02.Iftheline

isrebalancedwiththesameTakttimeandthemonumentalresourceboxchecked,thefollowing

balanceisgenerated.



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3. ThebalanceshowsthatactivityT06nowgetsassignedtostationST04.Thisresultsinthewhole

balancemovingupbyonestation.AstationNew1iscreatedtoaccommodatetheshift.

4. Themonumentalresourcesandthestationstheybelongtoshouldbekeptinmindwhiledrawingtheprecedencediagram.Ataskthatneedsatoolwhichisonthelatterhalfofthelinewillcreate

ariftinthebalanceifitisearl inthe recedence.



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3.2 Type II Balance

MinimizingtheTakttime(calledtheTypeIIbalance)requirestheusertospecifythenumberof

desiredworkstations.Inthisoption,ProBalancetriestominimizetheTakttimefortheavailablelist

oftaskswhileensuringthattheprecedencerelationshipismaintained.

StepstocreateaTypeIILineBalance

1. Afterdefiningtask,resourceandmodelinformation,savethescenarioandclickonthe

"BalancingStationView"intheViewmenu.Acellphoneexamplescenario isprovidedwiththis

manualandwillbereferencedinthisTypeIIlinebalancesection.Toloadthisscenariodata

clickon“File>OpenScenario”andthenclickCellphone.xml.

2.NextgototheBalanceStationViewandclickonthe"AutoBalance"iconinthemenubar(

Figure3.2-1).

Figure3.2-1: AutoBalanceicon

3. Selectthebalancetypeas"MinimizeTaktTime"andselectWeightedAverageBalance(Figure

3.2-2).4. NextprovidethedesirednumberofstationsandclickOK.Ifusingthecellphoneexample

scenario,typein3.

Note:Theusercannotspecifyanumberhigherthanthenumberofstationsdefinedinthestation

editor.Inordertoincreasethenumberofstationsinthebalance,addstationsinthestation

editor.



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Line Balancing

Figure3.2-2: Autobalancescreen

5. ThelinebalancegraphforthecellphoneexampleshowsthataTakttimeof27.98isneededfor

alltaskstobecompletedin3stations(Figure3).ClickonEdit>TakttimetorepresentTakt

timewithalineonthegraph.Belowthefigureisalistofdetailstonoticeaboutthegenerated

linebalance.

a.Station1hasfourtasks,whichistwicetheamountoftasksthestationcontainedinthe

TypeIexample.SincethegoalofaTypeIIlinebalanceistominimizethenumberof

workstations,moretaskswereassignedtoeachstation.

b.Station2hasamonumentalresourceviolation.Fixture02isnotavailableatthestation



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ST02.Theusercanrebalancethelineandthistimecheckthemonumentalresourcebox

toensurenomonumentalresourceviolationsoccurinthe eneratedlinebalance.

6. AswasthecasewithTypeIlinebalancing,theuserhastheoptiontorebalancethelineusingthe

peakmodelalgorithm.Pleasereferencethe TypeIBalancesectionortheGlossaryofthis

manualfordetailsonthedifferencebetweenweightedaverageandpeakmodel.

7. Usershavetheoptiontoreassignworkafterthelinebalancehasbeengenerated.Reference

theReassi nWorksectionofthismanualformoredetails.



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3.3 Reassign Work

Oncetheautobalancehasbeencompletedyoucanfurtherfinetunethebalancebymanually

movingworktodifferentstations.Toaccomplishthis,Rightclickonthetaskstobemoved,select

the'ChangeAssignment'option.Next,selectthestationand/oroperatortowhichthetaskshould

beassignedto(Figure3.3-1).Rebalancingthelineagainthroughthe'AutoBalance'optionwillbringbacktheoriginalbalance.

Figure3.3-1:ChangingTask'sStat ionAssignment



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3.4 Reports

StationSummaryReport

Thestationsummaryreportlistsallofthetasksforeachstationandoperator.Italsoprovides

workzone,model,option,time,resource,andpartsinformationforeachtask.

Figure3.4-1:Stat ionSummaryReport

BalanceReport

Thebalancereportprovidesutilizationandidletimesforeachstationandoperator.Italso

providesthetimebreakdownbymodelandcorrespondingutilizations.



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Figure3.4-2:BalanceReport

StationCompareReport

Thestationcomparereportcomparesscenariosandindicatestotheuserthetasks,resourcesandpartsthathavemovedfromtheiroriginalassignment.Thisisidealincomparinglinesoperating

atdifferentTakttimes.

1. ClickonthereportsmenuandselecttheStationCompareReport.



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Figure3.4-3:SelecttheStationstoCompare

2. NextselectScenariostobecompared.

3. Selectthecriteriaforcomparison,parts,toolsortasks.

4. Finallyselectthestationstobecompared.



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Line Balancing

Figure3.4-5:Task,Part ,andToolDiscrepanciesDispla yedinStat ionComparison

Report

ErgonomicsReport



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Figure3.4-6:ErgonomicsReport



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Setting up a scenario

4 Setting up a scenario

SettingupascenarioinProBalanceisafour-stepprocess:

1.SettingupModelData:Themodeleditorwillcontainthefourbasicmodelswiththeirdemandpercentagesdefined.

2.SettinguptheResourceData:Theresourceeditorwilllistallfixtures,solderguns,andtest

devices.

3.SettinguptheStationData:Thestationeditorshouldlistallstationsneededfortheprocess

andtheresourcesavailableatthosestations.Forthisexample,therewillbefivestations(ST01,

ST02,ST03,ST04,andST05).

4.SettinguptheTaskData:Enterdataonallthetasks(mentionedabove),theircorresponding

times,andthetoolstheyrequire.

TodemonstratetheProBalancescenariocreationprocess,acellphoneassemblywithfourdifferentmodeloptionswillbeusedasanexample.

CellPhoneModelTypes:

1. Basic:Acellphonewithacase,battery,keypad,anddisplay.

2. Standard:Acellphonewithacase,battery,keypad,display,andspeaker.

3. Deluxe:Acellphonewithacase,battery,keypad,display,andcamera.

4. Supreme:Acellphonewithacase,battery,keypad,display,speaker,andcamera.

Alongwiththemodels,optionalpartscanalsobeassociatedwiththesecellphonemodels.

CellPhoneOptions:1. Battery:4,6or8hourdurations

2. Display:RegularorColor

3. Camera:1.5xor3xopticalzoom



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Figure4-1: Cell phonemodels

Theassemblyprocessforthesephonesfollowsbelow.Basedonthemodeltype,eachcellphone

mayormaynotrequireeverytasklisted.

1. Assemblethelowercaseandplacethecircuitboard(usefixture01).

2. Placethemicroprocessorinthecircuitboard(Figure4-2).

Figure4-2: Microprocessor

3. PlacetheROM,radiosection,andthepowerunitnext(usethesolderinggun).

4. Placethecameraphoneunit.

5. Placetheflashmemorycardintothecardslotandsecure(Figure4-3).



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Figure4-3: Flashmemorycard

6. Placethedisplayunittothecircuitboardnext(usefixture02).

7. Nextplacethekeyboardpadontotheuppercase(Figure4-4).

Figure4-4:

Keyboardpad

8. Nextattachthespeakerunit(usefixture03).

9. Attachthebatterytotheboard.

10.TestbatterywithtestunitBT90(usetestingdeviceBT90).



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Figure4-5: Speakerunit

11

.

Attachtheantennatothecircuitboardandsecuretheupperandlowercasetogether.

12

.

Inspectpartfordefects(usetestingdeviceISP765).



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4.1 Single-Model Balance

Thesingle-modelbalanceoptionconsidersonlyonemodelbeingproducedonanassemblyline.

Usersdonotneedtodefineanymodelspecificdataforasinglemodelbalance.Thefollowing

stepsshouldbetakentosetupthecellphoneassemblyexamplescenario.

Resources

1.ClickontheResourceEditorundertheviewmenu(Figure4.1-1).

Figure4.1-1:AccessResource

Editor throughtheviewmenu

2. Provideresourcedetails:ID,Description,IsMonumental,etc(Figure4.1-2).

Figure4.1-2: Resourcedetails

Note:TheresourceFixture02isamonumentalresource.

Stations

1.Clickonthestationeditorundertheviewmenu Fi ure4.1-3 .



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Figure4.1-3:Accessstationeditor

fromtheviewmenu

2.Providedetailsandresourcesavailableateachstation(Figure4.1-4).

Figure4.1-4:Stationdetails

Note:ThemonumentalresourceFixture02isatthestationST02.

Tasks

1.Clickonthetaskeditorundertheviewmenu(Figure4.1-5).

Figure4.1-5:Accesstaskeditor

fromtheviewmenu

2. EnterthetaskdetailsintheTaskSheetnext,suchasID,andDescription.Afterthisis

completed,providetimedataforeachtask.Eachtaskinthecellphoneexample,contains

processtimeonly(Figure4.1-6).



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Figure4.1-6: Taskdetails

3.Oncethetaskstimesaredefined,nextmaptheresourcesbeingusedbythesetasks.Insteadof

scrollingleftandrighttoviewtheresourcestheusercansplitthetasksheetintoseparatepanes

(Figure4.1-7).

Figure4.1-7: Userscansplit thetasksheet intoseparatepanes

Note:TheresourceFixture02ismappedtotaskT06.

PrecedenceGraph

Theprecedencegraphdefinesarelationshipbetweentheactivitiesanddisplaystheorderinwhich

theactivitiesaretobedone.

1.ClickontheprecedencegraphtabatthebottomoftheTaskSheet.Allactivitiescanbeseen

here.Noticethatthereisno recedencerelationdefinedatthissta e Fi ure4.1-8 .



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Figure4.1-8: GraphwithPrecedenceUndefined

2. Startdefiningtherelationshipbetweenthetasksbyclickingatthecenterofthetasknodeand

releasingatthenexttask.Forourcellphoneexampletheprecedencediagramcanbeseenin

Figure4.1-9below.

Figure4.1-9: Precedencegraphdef inedbyuserforcell phoneexample

Aflowdiagram(Figure4.1-10)oftheprecedencediagramreadsasfollows:



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Figure4.1-10: Flowdiagramdescribingprecedencegraph

NowthatallofthedatahasbeenenteredintheResource,Station,andTaskEditors,aline

balancecanbegenerated.Referencethelinebalancingsectionofthishelpmanualtolearnthe

stepsnecessarytocalculatealinebalance(TypeIorTypeII)forthisscenario.



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4.2 Mixed-Model Balance

Themixedmodellinebalanceoptionconsidersa MIX,oraset,ofmodelsbeingproducedonthe

sameassemblyline.Usersneedtodefinemodelspecificdatawhenusingthisoption.The

followingstepsshouldbetakentosetupthecellphoneassemblyexamplescenario.

Models

1.Clickonthemodeleditorundertheviewmenu(Figure4.2-1).

Figure4.2-1: AccessModel

Editor fromtheviewmenu

2. Providethemodeldetails(ID,Description,andDemandPercentage),intheModelSheet(

Figure4.2-2).

Figure4.2-2: Modeldetails

3. Providetheoptiondetails(ID,Description,andPenetrationPercentage),intheOptionsSheet(

Figure4.2-3).



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Figure4.2-3: Optionsdetails

Resources

1.ClickontheResourceEditorundertheviewmenu(Figure4.2-4).

Figure4.2-4:AccessResource

Editor throughtheviewmenu

2. Provideresourcedetails:ID,Description,IsMonumental,etc(Figure4.2-5).

Figure4.2-5: Resourcedetails

Note:TheresourceFixture02isamonumentalresource.



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Stations

1.Clickonthestationeditorundertheviewmenu(Figure4.2-6).

Figure4.2-6:Accessstation

editor fromtheviewmenu

2.Providedetailsandresourcesavailableateachstation( Figure4.2-7).

Figure4.2-7: Stat iondetails

Note:ThemonumentalresourceFixture02isatthestationST02.

Tasks

1.Clickonthetaskeditorundertheviewmenu(Figure4.2-8).

Figure4.2-8:Accesstaskeditor

fromtheviewmenu

2. EnterthetaskdetailsintheTaskSheetnext,suchasID,andDescription.Afterthisis

completed,providetimedataforeachtask.Eachtaskinthecellphoneexample,contains

rocesstimeonl Fi ure4.2-9 .



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Figure4.2-9: Taskdetails

3.Oncethetaskstimesaredefined,nextmaptheresourcesbeingusedbythesetasks.Insteadof

scrollingleftandrighttoviewtheresourcestheusercansplitthetasksheetintoseparatepanes

(Figure4.2-10).

Figure4.2-10: Userscansplit thetasksheet intoseparatepanes

Note:TheresourceFixture02ismappedtotaskT06.

4.Mapthemodelsandoptionstothetasksnext(Figure4.2-11).



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Figure4.2-11: Mappingmodelsandopt ionstotasks

Rows4and8(Figure4.2-11)depicttasksspecifictothestandard,deluxe,andsuprememodels.Thesearetasksspecifictothespeakerandthecameraattachment.At

thisstagetheusercandefineoptionsifneeded(Example:cameracouldbea1.5xora

3x).

PrecedenceGraph

Theprecedencegraphdefinesarelationshipbetweentheactivitiesanddisplaystheorderinwhich

theactivitiesaretobedone.

1. ClickontheprecedencegraphtabatthebottomoftheTaskSheet.Allactivitiescanbeseen

here.Noticethatthereisnoprecedencerelationdefinedatthisstage( Figure4.2-12).



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Figure4.2-12: Precedencegraphundefined

2. Startdefiningtherelationshipbetweenthetasksbyclickingatthecenterofthetasknodeand

releasingatthenexttask.Forourcellphoneexampletheprecedencediagramcanbeseenin

Figure13below.

Figure4.2-13: Precedencegraphdef inedbyuserforcell phoneexample



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Aflowdiagram(Figure4.2-14)oftheprecedencediagramreadsasfollows:

Figure4.2-14: Flowdiagramdescribingprecedencegraph

NowthatallofthedatahasbeenenteredintheModel,Resource,Station,andTaskEditors,aline

balancecanbegenerated.Referencethelinebalancingsectionofthishelpmanualtolearnthe

stepsnecessarytocalculatealinebalance(TypeIorTypeII)forthisscenario.



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Single Model Tutorial

5 Single Model Tutorial

TutorialObjective:

Thistutorialsectionwillshowyouhowtocreateasinglemodellinebalance.Pleaseusethe

samplescenariofileSinglePumps.xml(locatedintheSamplesDirectoryofyourProBalance

folder)forthistutorial.

Step1:Openingascenario

I. OpenthetutorialscenariofilecalledSinglePumps.xml.File>OpenScenario.

Figure5-1:ToolbaroverviewII. Thedatawillloadintothetaskeditorasshownin Figure5-2below.Toviewthe

precedencegraph,clickonthe“PrecedenceGraph”tablocatedatthebottomofthetask

editor.

Figure5-2:TaskSheet intheTaskEditor

Step2:Editingthebasicdata

I. Editingthebasicdatainthe“TaskSheet”isverysimple.Spendafewminutesmodifying



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someofthedatacurrentlyinthesheet.TrychangingtheDescription,ValueAdded%(VA

%),Lineside,etc.IfyouchangetheprocesstimeorIDnumber,itwillaffecttheline

balanceresultsshowninthistutorial.SavethechangestothescenariobyclickingonFile

>SaveorSaveas.

II. Nextgotothe“PrecedenceGraph”tab,andtryeditinginformationintheprecedencegraph

(Figure5-3).DeletethearcfromPP01S-1toPP01S-2andaddanarcbetween40S-004

toPP01S-2.Todeleteanarc,clickonthearcandselectdeleteonyourkeyboard.Toadd

anarc,movethemousepointeraroundthecenterofthetaskfromwhichyouwanttodraw

thearc,leftclickanddragthearctothetaskyouwanttoconnectto.Savetheprecedence

diagram.Thediagramwillberedrawnoptimally(Figure5-4).

Figure5-3: PrecedenceGraphbeforethearcdelet ion

Figure5-4: PrecedenceGraphafter thearcdelet ion

Step3:Reviewing&editingstationsandresources

I. GototheStationEditor(View=>StationEditor)toviewtheworkstationsdefinedforthistutorial.

II. GototheResourceEditor(View=>ResourceEditor)toviewtheresourcesdefinedfor

thistutorial.

Note:Resourcetypesmaybeeither'Resource'or'Class'.Aclassisamoregeneralname

thatcontainsseveraldifferentindividualresources.Forexample,aclass"Drill"wouldlikely

containseveraldrills(DR01,DR02....)thataredefinedas'Resource'.



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III. Nowwewillpracticeusingclasses.Select"Class"intheTypecolumnandaddanew

classcalled‘Hoist’.Next,addanewResourcecalled‘Hoist-Fixture’(select"Resource"as

theType).Checkthe‘IsMonumental’box,whichmeansthattheHoist-Fixtureisa

monumentalresourceandcannotbeeasilymoved.Oncethisiscompleted,youshould

seesomethinglikeFigure5-5below.

Figure5-5: Addingaclassandresource

Step4:ReviewingPartsandContainers

I. GotothePartsEditor(View>PartsEditor).InthePartstab,reviewthepartsthathave

beendefinedforthistutorial.

II. Next,stillinthePartsEditor,movetotheContainerstab.Here,allofthecontainersused

topresentpartstothelineareshown.YoumayhavenoticedthataContainerIDofsome

partswasincludedinthePartsTab.Thecontainerstherewereselectedfromthelist

createdhere.



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Figure5-7:PartsEditorContainerTab

Step5:ReviewingConsumption

I. Next,wewilllookatconsumption.Afterascenariohashadpartsandcontainerssetup,

thepartscanbeassociatedwiththetaskthatwillconsumethem.ThisgivesProBalance

theabilitytoreportapartslistwitheachstationafterthebalance.Toreviewconsumption,

gototheTaskEditor'sConsumptionTab(View>TaskEditor>Consumptiontabat

bottom).II. Theconsumptioncanbeeditedinthistab--trymakingsomechanges.Anyofthecolumns

thatarewhite(PartID,Quantity,etc)maybeedited,butthegreycolumnsareread-onlyin

thistab.



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Figure5-8:TaskEditorConsumptionTab

Step6:Single-ModelLineBalance

I. Gotothepropertieswindow(File>Properties…)andchangethe‘LineType’to‘Single

Model’.

Note:Thiswillnotconsiderthevaluesdefinedinthe‘ModelSheet’ofthemodeleditor.

II. The‘OptionsSheet’intheModeleditorallowsdefiningoptions.Youcancreateoptions

here,andassigntheseoptionsinthetasksheettodifferenttasks.Bydoingso,theoptions

valueistakenintoaccountwhilecalculatingtheweightedtime.

Note:Youcanassignmultipleoptionvaluestoatask.Ifyouplantodoso,pleasecheck

thecalculatedweightedtimesforthetasks.

III. Gotothe‘BalancingStationView’(View>BalancingStationView).

IV. Select‘AutoBalance…’(Balance>AutoBalance)orselectitfromthetoolbar.Enter47

secondsastheDesiredcycletime(Takt).

Figure5-9: Autobalancemenu



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V. LeavetheremainingvaluesattheirdefaultsandSelect‘OK’.Amessagesayingthe

currentassignmentwillbeclearedwillbedisplayed(Figure7).Select‘Yes’tothis

prompt.

Figure5-10: Clearcurrentassignmentbeforeproceeding

VI. ProBalancewillnowautomaticallygenerateyourinitialtaskassignments( Figure5-11).

Figure5-11:ProbalanceLineBalance

VII. Thescreenview(above)showsthelinebalancefortheenteredcycletime(TaktTime).You

cannowselecttheappropriatestationforwhichtoviewtheworkassignment.Violations,

Resources,LineSide,etc.arealsoshowninthisview.

VIII. Iftasksrequiringaresourceoramonumentalresourceareassignedtoastationwithout

theresourceorifprecedenceisviolated,aviolationflagisdisplayed.Thesearethe

colored-incellsintheviolationcolumn.Clickingonaviolationwillgivemoreinformationat

thebottomoftheapplication.



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IX. Noticethattherewerenotenoughstationsinitiallydefinedinthe‘StationEditor’tomeetthe

specifiedTakttime,sonewstationswereautomaticallycreatedbytheapplication.

Step7:Manuallyfine-tuningthebalance

I. YoucanmanuallymovetasksbetweenstationsintheBalancingStationViewifyouwish.

Note:Whilemanuallymovingtasksaround,ProBalancewillallowyoutoexceedtheTakt

timeandviolateprecedenceconstraints.Thiswillbeevidentfromthechart,aswellasthe

stationsummarylistedinthelowerportionofthedisplay.

II. Gotostation‘BB001’.Rightclickontask‘40S-002’andselect‘ChangeAssignment’and

selectstation‘BB007’.Bydoingthisthestationtimeof‘BB007’hasexceededthespecified

Takttime(Figure5-12).

Figure5-12: Stat ion

BB007

III. Gotostation‘BB002’.Youwillseeaprecedenceviolationfortask‘40S-003’.Clickingon

‘P’showsthetaskthatiscausingtheviolation(inthiscase‘40S-002’).

Figure5-13: Precedenctviolat ion

IV. Refertotheprecedencediagramtoverifytheaboveviolation(View>TaskEditor=>

PrecedenceDiagram)



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Figure5-14: Precedencediagram

V. Youcanalsoexcludeataskfromthebalance.Rightclickonrowcontaining40S-001and

select“RemoveAssignment”.Thetaskisremovedfromthestationandthecycletimeof

thestationisreduced.Thetaskismovedtothe“UnassignedProcesses”totheleftofthe

screen.

VI. Clickingonthe“UnassignedProcesses”showstheunassignedtask“40S-001”.Rightclick

onthetaskandassignittoStationBB0002.

Step8:Searching

I. Taskscanbesearchedbyinvoking‘Find’(Edit=>FindorCTRL+F)inthe“Balance

StationView”.Figure5-15belowshowsthevariouscriteriawithwhichyoucansearchfor

tasks.Trysearchingforanytaskwithanettimegreaterthan3seconds.SelectNetTime,

typein>3,andclick'Find'.

Figure5-15: Findcommand

Step9:Reports

TherearefourreportsthatcanbegeneratedintheReportsmenu;examplesofthetwomost-used

appearbelow:

I. BalanceReport:Inadditiontodisplayingindividualcycletimesandutilizationperstation,

thisreportalsogivessummarystatisticsatthetop.Thesummaryincludesthemaximum

value,minimumvalue,andaveragevalueforstationidletime,idletime,andutilization.



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Figure5-16: Balancereport

II. StationSummary:Thisreportgivesdetailedinformationforeachstationincludingwhich

tasksareassignedtothestation,theresourcesrequiredatthestation,andwhich

resourcesareconsumedthere.



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Figure5-17: Stat ionsummaryreport



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Mixed Model Tutorial

6 Mixed Model Tutorial

TutorialObjective:

Thistutorialwillshowyouhowtocreateamixedmodellinebalance.Pleaseusethesample

scenariofileMixedPumps.xml(locatedintheSamplesDirectoryofyourProBalancefolder)for

thistutorial.


I. Openthetutorialscenariofilecalled“MixedPumps.xml”.“File>OpenScenario”.

Figure6-1:Toolbaroverview

II. Thedatawillloadintothetaskeditorasshownin Figure6-2below.Toviewthe

precedencegraph,clickonthe“PrecedenceGraph”tablocatedatthebottomofthetask

editor.



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Figure6-2: Tasksheetinthetaskeditor

Step2:Editingthebasicdata

I. Editingthebasicdatainthe“TaskSheet”isverysimple.Spendafewminutesmodifying

someofthedatacurrentlyinthesheet.TrychangingtheDescription,ValueAdded%(VA

%),etc.IfyouchangetheprocesstimeorIDnumber,rememberthatyourlinebalance

resultswillnotmatchthoseshownhere.YoumaysaveanychangestothescenariobyclickingonFile>SaveorSaveas.

II. Nextgotothe“PrecedenceGraph”tab,andtryeditinginformationintheprecedencegraph.

(Again,changesmeanthatyourresultswillnotmatchthoseshownbelow).Todeletean

arc,clickonthearcandselectdeleteonyourkeyboard.Toaddanarc,movethemouse

pointeraroundthecenterofthetaskfromwhichyouwanttodrawthearc,leftclickand

dragthearctothetaskyouwanttoconnectto.Anytimethechangesaresaved,the

diagramwillberedrawnoptimally.

Step3:Reviewing&editingstationsandresources

I. GototheStationEditor(View>StationEditor)toviewtheworkstationsdefinedforthis

tutorial.

II. GototheResourceEditor(View>ResourceEditor)toviewtheresourcesdefinedforthis

tutorial.

Note:Resourcetypesmaybeeither'Resource'or'Class'.Aclassisamoregeneralname

thatcontainsseveraldifferentindividualresources.Forexample,aclass"Drill"wouldlikely

containseveraldrills(DR01,DR02....)thataredefinedas'Resource'.

Step4:ReviewingPartsandContainers



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I. GotothePartsEditor(View>PartsEditor).InthePartstab,reviewthepartsthathave

beendefinedforthistutorial.

II. Next,stillinthePartsEditor,movetotheContainerstab.Here,allofthecontainersused

topresentpartstothelineareshown.YoumayhavenoticedthataContainerIDofsome

partswasincludedinthePartsTab.Thecontainerstherewereselectedfromthelist

createdhere.



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Figure6-4:PartsEditorContainerTab

Step5:ReviewingConsumption

I. Next,wewilllookatconsumption.Afterascenariohashadpartsandcontainerssetup,

thepartscanbeassociatedwiththetaskthatwillconsumethem.ThisgivesProBalance

theabilitytoreportapartslistwitheachstationafterthebalance.Toreviewconsumption,

gototheTaskEditor'sConsumptionTab(View>TaskEditor>Consumptiontabat

bottom).II. Theconsumptioncanbeeditedinthistab--trymakingsomechanges.Anyofthecolumns

thatarewhite(PartID,Quantity,etc)maybeedited,butthegreycolumnsareread-onlyin

thistab.



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Figure6-5:TaskEditorConsumptionTab

Step6:Mixedmodelbalance

I. GotoFile>PropertiesandcheckthatMixedModelBalancehasbeenselected.Ifnot,

selectit.

II. GototheModelEditor(View>ModelEditor).Withthe‘ModelSheet’tabinvoked,youwill

seeLargePump,MediumPumpandSmallPump.Changethedemandvaluesto0.2,0.4,

and0.4respectively.ThesevaluessetthedemandfortheLargePumpat20%andthe

demandfortheMedium&Smallpumpsat40%each.

Note:Forpropercalculation,thedemand%valuesshouldaddupto1.

III. Next,gotothe‘BalancingStationView’(View=>BalancingStationView).SelectAuto

Balance(Balance=>AutoBalance).Entercycletime= 47 andselect‘OK’.

Figure6-6: Autobalancemenu

IV. Select‘Yes’tothefollowingmessagewarningaboutclearingexistingassignments.



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Figure6-7: Clearexist ingassignments

V. ThefollowingbalanceshowninFigure6-8willbegenerated.

Figure6-8:GeneratedBalance

VI. Thechart(above)documentsamixedmodelbalanceshowingthetimespentbyeach

modelineachstationandtheaveragetimeconsideringthemodeldemand%and

penetration%.Pleasenotethatforindividualmodels,thegraphshowstheactualtime

spentbyeachmodelineverystation.Sincetheaveragetimebarconsidersthemodel

demand%andpenetration%,thereisapossibilitythattheaveragetimeisnota

straightforwardmathematicalaverageofthemodeltimes.

Step7:Manuallyfine-tuningthebalance

I. YoucanmanuallymovetasksbetweenstationsintheBalancingStationViewifyouwish.

Note:Whilemanuallymovingtasksaround,ProBalancewillallowyoutoexceedtheTakttimeandviolateprecedenceconstraints.Thiswillbeevidentfromthechart,aswellasthe

stationsummarylistedinthelowerportionofthedisplay.

II. GotostationBB002.Rightclickontask40S-003.Select‘ChangeAssignment’andassign

ittostationBB003.ThishascausedthestationtimeofBB003toexceedthespecifiedTakt

time,asyoucanseeintheProBalancegraph.

III. Youmayalsoexcludeataskfromthebalance.Rightclickonrowcontaining40S-003and

select'RemoveAssignment'.Thetaskisremovedfromthestationandthecycletimeof



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thestationisreduced.Thetaskhasbeenmovedtothe“UnassignedProcesses”totheleft

ofthescreen.

V. Clickingonthe“UnassignedProcesses”showstheunassignedtask40S-003.Rightclick

onthetaskandassignittostationBB0002.

Step8:SearchingI. Taskscanbesearchedbyinvoking‘Find’(Edit>FindORCTRL+F)inthe“Balance

StationView”.Figure6-9belowshowsthevariouscriteriawithwhichyoucansearchfor

tasks.Trysearchingforanytaskwithanettimegreaterthan3seconds.SelectNetTime,

typein>3,andclick'Find'.

Figure6-9: Findcommand

Step9:Reports

TherearefourreportsthatcanbegeneratedintheReportsmenu;themost-usedtwoappear

below.Thesereportsconsidermultiplemodels.



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7 Manual Balance Tutorial

TutorialObjective:

Thistutorialsectionwillshowyouhowtocreateamanuallinebalance.Itwillalsoteachyouhow

tousegroupingandmultiplezonesonaline.Pleaseusethesamplescenariofile SinglePumps.

xml(locatedintheHelpDirectoryofyourSamplesDirectoryofyourProBalancefolder)forthis

tutorial.


I. Openthetutorialscenariofilecalled“SinglePumps.xml”.“File>OpenScenario”

II. Forclearingtheexistingtaskstationassignments,goto‘BalancingStationView’andthen

selectBalance=>ClearAllAssignments.

Figure7-1:Clearal l assignments

III. Next,gotoFile>PropertiesandchecktheEnableWorkZoneConstraints.Thiswillallow

youtoassignworktomultiplesidesoftheline.



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Manual Balance Tutorial

Step2:AssigningGroupsI. GototheTaskEditorandselecttheTaskGroupingtab.Highlightactivities‘40S-001’and

‘40S-002’,rightclickandselect‘AddtoGroup…’.

II. Createanewtaskgroup‘U-Cup’.



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III. Anewgroupbythenameisadded‘U-Cup’isadded.

Figure7-5:Groupedtasks

Step3:Assigninglinesides

I. Gotothe‘TaskSheet’tabandassignazone.Changethezoneof‘40S-001’and‘40S-002’

toRight.

Figure7-6:Changel inesidefor twotasks

II. Similarlymakethetask‘PP01S-5’arightsidetasktoo.

Step4:Manuallybalancing

I. Goto‘BalancingStationView’.(View>BalancingStationView)andopenthe‘Unassigned

Processes’windowontheleft.

Hint:Youcananchorthe‘UnassignedProcesses’byclickingonthetop-rightbutton.

Selectitagaintocloseit.

II. AssignaTakttime(Edit>TaktTime)andchangeitto50,whichessentiallyserveasa

markerinthegraphandforreportingpurposes.

III. Selecttasks1through5inthe‘UnassignedProcesses’list,rightclickandassigntostation

‘BB001’.Anerrorisshownthatarightsideactivitycannotbeassignedtothelefthandsidestation.Notethatallstationsareleftsidestations.

IV. GototheStationEditorandchangestation‘BB002’torightsideandgobacktothe

‘BalancingStationView’.

V. Nowassignactivity5&6(PP01S-5&40S-001)tostation‘BB002’.Whiledoingso,task#7

(40S-002)willalsobeassignedtostation‘BB002’astheybelongtothesamegroup.

VI. Completeassignmentoftheremainingtasksmanually.Youcangeneratethereportsby

clickingontheReportmenuandselectingtheappropriateoption.



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Manual Balance Tutorial

Note:Youcouldalsoautomaticallyassignallofthetaskstostationsandthenmanually

changetheassignmentsofselectedtasks.Rememberthatifyoumoveataskthatisa

memberofagroup,theentiregroupoftaskswillbemoved.



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8 Multiple Operators Tutorial

TutorialObjective:ThistutorialsectionwillshowyouhowtousetheMultipleOperatorsfeature.

Ourpreviousapproachtolinebalancingrestrictedtheusertoonlyoneoperatorperstation.With

thisversiontheusercandefinemultipleoperatorsperstation.

I. BeginbyopeningtheMixedPumps.xmlscenario.Currentlythebalancehasoneoperator

perstation.

Figure8-1: Stat ioneditorv iewcontainingnumberofoperatorsperstat ion

II. Gotothe‘BalancingStationView’(View=>BalancingStationView).SelectAutoBalance

(Balance=>AutoBalance).Entercycletime=30andselect‘OK’.Notethatwithone

operatorperstationthereareatotalofsevenstations.



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Multiple Operators Tutorial

Figure8-2: Linebalancegeneratedwithoneoperatorperstat ion

III. Nowswitchbacktothestationeditoranddefinetwooperatorsinstationone.

Figure8-3: Definetwooperators instat ion#1

IV. Gobacktothe‘BalancingStationView’(View=>BalancingStationView).SelectAuto

Balance(Balance=>AutoBalance).Entercycletime =30andselect‘OK’.Withmore

operatorsinthisstation,theamountofworkthatcannowbeassignedtothisstation

BB001hasbeendoubled.Alsonotethatstationsevenisnowempty. Thebalance

howeverdoesnottakecareofthePrecedenceorderinbetweenoperators. For

example,ifoperator1startsTask1,operator2hastowaitforhimtofinishthetaskbefore

hecandoanything(duetoPrecedence).Inthisbalanceitassumesbothoperatorscan

starttheirtaskssimultaneously.



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Figure8-4: Linebalancegeneratedwithtwooperatorsatstat ionBB001

V. Thetasksarenowassignedtotwooperators.ThealgorithmensuresthatthetimeperoperatordoesnotexceedTakttime.VI. Clickontheoperatorviewtoseetheworkassignmentperperson.Theusercanalso

shuffleworkinbetweentheoperators.



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Figure8-5:Operatorview

VII. Inordertomovework,followthesametechniqueasmovingworkbetweenstation.Right

clickonthetask,selectthestationandthenselecttheoperatortowhomthetaskhastobe

assignedto.



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Figure8-6: Assigningtaskstoaspecif icoperator

VIII.Oncethebalanceiscomplete,ReportscanbegeneratedfromtheregularReportsmenu.

TheoperatorcolumninthereportswillcontainbothOperator1andOperator2,to

differentiatebetweenworkassignedtodifferentoperators.



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9 Clusters and Lean Graph Tutorial

TutorialObjective:Thistutorialhastwosections.Thefirstsectionwillshowyouhowtousethe

Clustersfeature.Ourpreviousapproachtotheprecedencegraphrequiredtheusertodrawthe

graphfortheentireline.Withthisversiontheusercandefineclustersorgroupingsoftasksand

proceedoneclusteratatimeinsteadoftheentireline.Thesecondsectionwillfocusonthelean(valueadded/nonvalueadded)graph.

SectionI-Clusters

I. BeginbyopeningtheMixedPumps.xmlscenarioandclickonthePrecedenceGraphon

thetasksheet.SettheViewTypetoCluster.Currentlythescenariohasonlyonecluster,

theDefaultcluster.

II. Next,definesomenewclustersclusters.Wewilldefinetwomoreclusters,sayCLS1and

CLS2.InordertodosotypethenamesoftheclustersintheClustercolumnandclick

Refresh.



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Clusters and Lean Graph Tutorial

III. Next,associatetaskstoeachcluster.Todothis,changetheViewTypetotaskgraph.The

listofalltaskswillappearinthespreadsheet.

IV. Nowmodifytheclustercolumnnexttoeachtask.Sinceclustershavebeencreated,the



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clustercolumnnowhasadrop-downlistofalltheclusters.Simplyclicktoassignataskto

acluster.Youcanalsodraganddroptheclustercolumntoassignmultipletaskstothe

samecluster.Notethatwhenyouassignatasktoacluster,theexistingprecedence

informationforthattaskisdeleted.

V. Oncetheclustershavebeenassignedtotasks,clickontheclusterdropdowntoview

tasksthatbelongtoacluster.Therewillbenoprecedencedefinedwithintheclusters;you

maynowgointoeachclusteranddefine aprecedencerelationship.



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VI. Finally,definearelationshipbetweentheclusters.Inordertodothis,changetheViewType

toCluster.Youmayeitherdefinetheprecedenceinthespreadsheetordrawlinesonthe

graph.



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SectionII-LeanGraph

Theleangraphhelpstheuservisualizetheamountofvalue-addedworkateachstation.

1. Definethevalue-added,non-value-addedandnon-value-added-but-necessarypercentagesfor

eachtaskintheTasksheet.



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2.Oncethesetasksareassignedtostations,theresultinglinebalancegraphlooksliketheone

shownbelow.Youneedtocheckthe'ShowVA/NVAchart'box.TogetbacktotheregularLine

Balancegraph,simplyuncheckthisbox.



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Station Compare Report Tutorial

10 Station Compare Report Tutorial

TutorialObjective:Thistutorialcoversthestationcomparereport.Thisreporthighlightstothe

usertasks,toolandpartsthathavechangedassignmentsincethelasttimethelinehadbeen

balanced.

I. BeginbyopeningtheMixedPumps.xmlscenario.

II. Next,opentheBalancingStationView.Thetask40S-001iscurrentlyinstationBB001.The

taskhastheparts-10000001-ORing(viton)for2,10000002-Oringfor15mappedtoit.

Thistaskalsohasthetools-FIXTURES1,L-OILmappedtoit.

III. WewillnowmanuallymovethistasktostationBB003,andthenrunourcomparisonreport

tohighlightthechanges.



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IV. Oncethetaskisreassignedsavethisscenariounderadifferentname,inthiscasewe

havesaveditasMixedPumps-II.xml .Thetaskinthenewscenarionowappearsin

stationBB003.



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V. Inordertorunthereport,selectthereportsmenuandselecttheScenarioCompareReport

option.

VI. Nextselectthetwoscenariostobecompared,inthiscaseitwillbeMixedPumps.xml

andMixedPumps-II.xml.Selectthecriteriaforcomparison,tools,tasksorparts.Finally

selectthestationstobecompared.



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VII. Wenowwillrunthecomparisonreport.Thisreportisforeachstationandhasthree

sections,firstdisplaysthetasksthathavemoved,thesecondsectiondisplaysthe

resourcesthathavemovedandthethirdsectionreportsaboutthepartsthathavemoved.

Comparison

TaskComparison-Task40S-001movedfromBB001toBB003.



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ToolComparison-NotethePreviousstationcolumninthereport,thisindicatestotheuser

thatthetoolsthatneedtobemovedtothenewstation.



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PartsComparison-Similartothetools,thepartssectionalsohasthepreviousstationcolumn

indicatingtotheuserthestationfromwherethepartscamefrom.



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11 Space Utilization Tutorial

TutorialObjective:Thistutorialwillshowyouhowtoviewthespaceutilizationbystation.

Pleaseusethesamplescenariofile Automotive.xml(locatedintheSamplesDirectoryofyour

ProBalancefolder)forthistutorial.

Thespacerequirementsarecomputedforastation.Theavailablespaceiscomparedtothe

footprintofthepartcontainersandresourcesassignedtothatstation.Thisimpliesthattheuser

needstosetupthedimensionsforthestation,partcontainerandtheresources.

1. BeginbyopeningtheAutomotive.xmlscenario.

2. ClickonViewandselecttheBalancingStationViewoption.

3. Observethebalancegraph,youwillnoticethatstationV001Dhasanoverfilledstation.Please

seeimagebelow.



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Space Utilization Tutorial

4. NextclickontheViewmenuandselecttheStationEditor.

5. InherechangethelinesidewidthforstationV001Dto1200.Note:theunitofthiswidth

shouldbethesameasthewidthsofthepartcontainersandresources.

6. Gobacktothebalancingstationviewandlookatthespaceutilizationgraphagain.Youwillnote

thatthestationV001Disnolongeroverutilized.



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7. Nextstepistoprovidethepartcontainerdimensions.OpenthePartsEditorfromtheview

menu.

8. Therearetwotabsinthiseditoroneforthepartandtheotherforthecontainers.Ensurethatthe

partshavecontainersmappedtothesame.

Wewillmodifythelinesidewidthsofthefollowingcontainer-10373373and10375824.

10373373-changefrom63to100

10375824-changefrom63to200

9. Theresultinggraphisasbelow.Notethatthereisnomorefreespaceatthestation.



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Space Utilization Tutorial

10.Finallywewillmodifythelinesidewidthofaresourceatthisstation.ClickontheViewmenu

andselecttheresourceeditor.

11.Modifythelinesidewidthsofthetworesources-SPACERANDTORQ001from60to100.

12.Nextgobacktothebalancingstationviewandseethespaceutilization,thestationisnowover

utilized.



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Consumption Tutorial

12 Consumption Tutorial

TutorialObjective:Thistutorialwillshowyouhowtoassociatepartstotasks.Pleaseusethe

samplescenariofileAutomotive.xml(locatedintheSamplesDirectoryofyourProBalancefolder

)forthistutorial.

1. ClickonViewandPartsEditor.

2. AddtwonewpartsinherePart01:BoltandPart02:Cap.



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3. ClickonViewandselecttheTaskEditandthenclickontheConsumptiontabintheTaskEditor.

4. InherefortaskT0001selectthepartPart01inPartIDcolumndropdownlist.Nextrightclickon

thePartIDandselecttheInsertoption.Thiswilladdarowatthebottom.

5. Intherowbelow,nowselectthesecondpartPart02fromthelist.Thiswillnowassociatetwo

partswiththetask.



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Glossary

13 Glossary

Glossary

ABCDEFGHIJKLMNOPQRSTUVWXYZ

Top

B

Balance:

· TypeIBalance:MinimizingthenumberofStations requirestheusertospecifyaTakttimeinordertodeterminewhichtasksgetassignedtowhatstations.Inthissituation,ProBalance

triestominimizethenumberofstationsrequiredfortheavailablelistoftasks,whileensuringthat

theprecedencerelationshipismaintained

· TypeIIBalance:MinimizingtheTakttime,requirestheusertospecifythenumberofdesired

workstations.Inthisoption,ProBalancetriestominimizetheTakttimefortheavailablelistof

taskswhileensuringthattheprecedencerelationshipismaintained.

Top

C

CSVor.csvFiles

AcommaseparatedvaluefileoraCSVfileisonewhereallthecolumnswithinthefileare

separatedbyacomma.MicrosoftExcelhastheoptionofsavinganyfileasa.csvfile.

Clusters

Aclusterisagroupoftaskswithaprecedencerelationshipdefined.Theuserwouldcreate

clusterstoeasetheprocessofdefiningprecedence,insteadoflookingatthecompletelinethe

usercannowprocessclusterbycluster.

D

DemandPercentage

Apercentagethatdepictsthedemandoftheproduct.Forexample,imaginetherearethree



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products(A,BandC)beingmanufactured.Amonthsdemandrequiresatotalof200A's,400B's

and400C's.Basedonthis,thedemandpercentagewouldbe0.20forproductAand0.40for

productsBandC.

Top

E

Top

F

FlowPlanner

FlowPlannerisamaterialhandlinganalysistoolthatrunsontopofanAutoCADlayout.Itaidsin

analyzingmaterialflowthroughoutthefacility.

Top

G

Grouping

Allowstheusertogrouptasks/activitiesthatalwaysneedtobedonetogether.Thisisespecially

importantduringarebalancesinceasetofgroupedtasksmovesasasingleentity.Top

H

Top

I

Import

ReferstotheprocessofaddinganexternalfileintotheProplannerapplication

Top

L

http://www.proplanner.com/Product/Details/flowpath.aspx



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Glossary

M

MixedModelBalance

Alinebalancewithamixtureofmodelsgoingdowntheline.Eachmodelhasaspecificdemand

percentageassociatedwithit.

MonumentalResources

Theseareresourcesthatarefixedataspecificlocationontheplant(hoist,fixture,machine,etc.)

Top

O

Operators

Proplannerallowsmultioperatorsperstation.Bydefaulteachstationcanbetreatedasanoperator(i.e.Oneoperatorperstation).

***

Top

P

PeakModelBalance

Thepeakmodelbalanceortheconservativebalancecheckstomakesurethatthemodelwiththe

highesttimeisbelowtheTakttimesetbytheuser.Bylocatingthemodelwiththehighesttime,

ProBalanceensuresthatnoneofthemodelsexceedtheTakttimeinagivenstation.Forexample,

considerataskT1(assemblingaheatshieldonanengine)thatisapplicabletomodelsM1and

M2.ThetasktakestwominutesformodelM1whereasforM2thetasktakesfiveminutes.The

peakbalancelogicwillmakesurethatthetasktimeforM2iswithintheTakttime,thus

automaticallytakingcareofM1.AlsoseeWeightedAverageBalance.

Top

R

Resource

Operator,machineortoolthatcontainsafixedandvariablecost,andisusedtoperforman

activity.ResourcesarereferencedbyactivitiesandassignedtolocationswithinProBalance.Each

resourcecanbespecifiedbyclass(lathe,operator,etc.)orbyaninstanceofaclass(lathe16or

operator12).Userscanalsodefineadditionalresourcetypesassub-typesofthesebasetypes:



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Machine

MaterialHandlingDevice

Operator

Tool

ConsumableImport

Resourceblocksfoundwithinalayoutdrawingthathavenotyetbeendefinedintheprojectare

collectedunderthenode“Import”.Intheplantview,aresourceisalwaysachildofactivity

locationsandareglobaltoanaccount.

Top

S

SingleModelBalance

Alinebalancewithonlyonemodelbeingproducedontheline.

Top

T

TaktTime

Thespeedatwhichpartsmustbemanufacturedinordertosatisfycustomerdemand.

Top

U

Userclass(UC)

Auserdefinedclassusedtoclassifyresources.

Top

V

Valueaddition

Apercentageorabinaryvaluethatshowshowmuchvaluethatprocessadds.Version

Proplannerentitiescanhavevariantsofitself,whicharedifferentiatedbyassigningversion

numbers.

Top

W



126Glossary

WeightedAverageBalance

Theweightedaveragebalanceconsiderstheweightedtimesofthedifferentactivitiesandensures

thattheyarewithintheTakttimespecifiedbytheuser.Thisfeatureisapplicableonlyformixed

modelbalancing.Consideralinewithtwomodels(M1andM2)forexample.M1hasa60%

demandpercentageandrequiresaT1taskandM2hasa40%demandpercentageandrequiresa

T2task.T1hasaprocesstimeof10minutesandT2hasaprocesstimeof12minutes.The

weightedaverageforT1andT2,inthisexample,wouldbe(10*(0.6)+12*(0.4)=10.8).This

meansthatthelinecouldbesetatan11minuteTakttimeandstillbebalanced.Althoughonetask

(T2)isexceedingtheTakttimetheweightedaveragetimeisstillbelow11minutes.Alsosee Peak

ModelBalance.

Work-station

See'Station”

WorkPlacePlanner

TheWorkplacePlannertakesthehassleoutofdiagrammingoperatorwalkpaths,calculating

stationcycletimesandwalkdistances,determiningLEANworkcontent,andevaluatingergonomic

liftandcarryissues.

Zones

Astationcouldhavemultiplezones,indicatingthattheoperatorcanworkindifferentareasofthe

workstation.Inordertoaddzones,createacommaseparatedlistoftheapplicablezonesandmapthemtoastation.

http://www.proplanner.com/Product/Details/WorkplacePlanner.aspx

ProBalanceManual_2F1EC6B40055E

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