ANALYSIS OF AUTAOMATED FLOW LINES

In analyzing the performance of automated flow lines, two general problem areas must be distinguished. The
first is related to the production processes used on the line. For example, consider a transfer line that performs a
series of machining operations. There is an extensive body of knowledge related to the theory and practice of
metal machining. This technology includes the proper specification and use of cutting tools, the metallurgy and
mach inability of the work material, chip control, machining economics, machine tool vibrations, and a host of
other topics. Many of the problems encountered in the operation of a metal-cutting transfer line are directly
related to and can be solved by the application of good machining principles. The same is true for other
production processes. In each area of production, a technology has developed after many years of research and
practical experience in the area. By making the best use of the given process technology, each individual
workstation on the line can be made to operate at or near its maximum productive capability. However, even if
it were possible to operate each station in an optimal way, this does not guarantee that the overall flow line will
be optimized.
It is with this viewpoint of the overall flow line operation that we identify the second general problem area of flow line
performance. This second area is concerned with the systems aspects of designing and running the line. Normally
associated with the operation of an automated flow line is the problem of reliability. Since the line often operates as a
single mechanism, failure of one component of the mechanism will often result in stoppage of the entire line. There are
approaches to this problem that transcend the manufacturing processes at individual stations. In addition to the reliability
problem, another systems design problem is one of properly balancing the line. In line balancing, the objective is to
spread the total work load as evenly as possible among the stations in the line.

GENERAL TERMINOLOGY AND ANALYSI

Flow line performance can be analyzed by means of three basic measures:
Average production rate,
Proportion of time the line is operating (line efficiency),
And cost per item produced on the line.