Swarm Intelligence: Bucket Brigade Assembly Lines Presented by Steve Schmitz

Overview Bucket Brigade Overview Bucket Brigade Operation Design Guidelines Benefits

Bucket Brigade Overview Flow line Less workers than stations Each worker carries their work with them Sequence of workers maintained Last worker ‘pulls’ work through the line

Bucket Brigade Overview (cont) Operations Raw Material In Workers Finished Product Out

Overview Bucket Brigade Overview Bucket Brigade Operation Design Guidelines Benefits

Typical Operation Work divided into ‘cells’ Each batch has some process time Each station performs some % of total process Output of one cell is maximized

Calculating Throughput Simplifying assumptions Identical workers 1 worker  1 machine Reset time is negligible Circular flow line/Closed queue

Calculating Throughput (cont) Throughput limited by: 1 worker  1 batch/time unit 1 worker  1 machine Production Rate: MIN{n, 1/pmax}

Calculating Throughput (cont) Production limitations translate to: Overstaffing Bottlenecks Conclusion: workers will self organize to time intensive tasks

Overview Bucket Brigade Overview Bucket Brigade Operation Design Guidelines Benefits

When to use a Bucket Brigade Work is variations on limited skills Work is easily transferable Work stations are inexpensive in relation to workers Demand varies

Design Guidelines Worker quantity < machine quantity stations≈2.5*workers Use smaller teams Pick appropriate batch sizes Large batches if transfer costs are high Small batches if handling costs are high

Overview Bucket Brigade Overview Bucket Brigade Operation Design Guidelines Benefits

Benefits of a Bucket Brigade Industry consistent Pull system No special material handling Self balancing Simple

Questions/Discussion