1. Using the queuing-theoretic approximations for the performance of “push” and “pull” production lines to address Design Problems

2. A variety of production line design problems
Select the “technology options” and the production capacity to be deployed at the various stations of a “push” line so that the line can sustain a target production rate with a specified (expected) lead time, and the deployment cost is minimized.
Select the “technology options” and the production capacity to be deployed at the various stations of a “push” line so that the line supports a target production rate, a certain budget limit is not exceeded, and the resulting cycle time is minimized.
Reduce the cycle time of an existing line to a target level, by choosing from a number of possible modifications, while minimizing the resulting cost.
Set the number of cards of a CONWIP line to a certain level so that the line can produce at a target throughput rate.
Design a CONWIP line that can support a certain throughput with a target WIP level

3. A “generic” methodology
Organize an (efficient) search within the space of feasible solutions.
Evaluate each contemplated candidate using the relevant approximating formulae regarding the system WIP, CT and TH.
Employ the insights provided by the aforementioned formulae and the underlying computations in order to identify an improving candidate.

4. Example The above data correspond to the effective processing times.
Design of a new 4-station assembly line for circuit board assembly.
The four consecutive stations and the currently considered “technology options” for them (each option defines the processing rate in pieces per hour, the CV of the processing time, and the cost per unit in thousands of dollars).
The above data correspond to the effective processing times.
Each station can employ only one technology option.
The maximum production rate to be supported by the line is 1000 panels / day.
The desired average cycle time through the line is one day.
One day is equivalent to one 8-hour shift.
Workpieces will go through the line in totes of 50 panels each, which will be released
into the line at a constant rate determined by the target production rate.
Design task: Identify a line configuration that meets the above requirements while
minimizing the equipment cost.
Also, estimate the expected WIP at every station, when the line is operated at
maximum production rate.

5. Assembly Line Balancing (ALB)

6. Synchronous Transfer Lines: Examples (Pictures borrowed from Heragu)

7. Problem Statement
Given:
a set of m tasks, each requiring a certain (nominal) processing time t_i, and
a set of precedence constraints regarding the execution of these m tasks,
assign these tasks to a sequence of k workstations, in a way that
the total amount of work assigned to each workstation does not exceed a pre-defined “cycle time” c, (constraint I)
the precedence constraints are observed, (constraint II)
while the number of the employed workstations k is minimized. (objective)
Remark: The problem is hard to solve optimally, and quite often it is addressed through heuristics.