To design a line that perfectly suits your needs, you need to accomplish the following steps.

1. Input all necessary data

    All of OptiLine's data are stored in a single project file, in a format editable by spreadsheet programs such as Microsoft Excel. There are the following types of data:

• The definition of the product(s) / assembly process. These data define the operations to be performed on the line, with all applicable attributes (mandatory and optional). Operations are edited in the Operations Tab. Possible variants of the product being assembled are specified in the Variant Editor or the BOM dialog, depending on the variant model used. When the BOM is ised, it is possible to define relevant product models which will be taken into account by the optimizing algorithm. Possible zoning constraints are edited in the Zoning dialog. A fully customizable set of ergonomic constraints (working positions) can also be defined.
• The definition of the assembly line. These data define the workstations in the line, with all applicable attributes. The graphical editor in the Workstation Tab makes it easy to model an existing line, or to define a future one.
• Constraints. These data define optional constraints imposed on the operations and/or workstations so that an assignment of operations to workstations (manual or automatic) be feasible w.r.t. the production constraints the line designer faces. They also make it possible to fix portions of an existing line, so that only the parts of the line that can change will possibly be modified.

2. Run the optimization

    Once the data are specified, the automatic balancing can be run. The algorithm can be run with no operations assigned (empty line), or with an existing assignment already present. In both cases, the algorithm returns an assignment of operations to workstations (and, possibly, operators) that is optimized and complies with all constraints specified above. In rare situations, the constraints may be extremely difficult or outright impossible to satisfy, in which case the algorithm reports a failure, prompting you to relax the constraints and restart the algorithm.
    Note that with explicit variants, or when product models are defined with a BOM, it is possible to take into account the peak times at workstations in the optimization, by setting the appropriate control in the Optimize Dialog. A line with reduced peak times is less sensitive to the order of execution of the various variants or models, requires less buffer space in front of workstations, and is generally easier to run and manage.
    The optimization can be run on your local computer or, if you have the required privileges, on the remote server.

3. Examine the results

    The result of the optimization, an assignment of operations to workstations/operators, is returned by the algorithm (or downloaded from the remote server) in form of a new project, leaving the initial project untouched. This allows for a very convenient comparison of an optimized line with an non optimized one, or indeed various versions of the same line (obtained e.g. with different sets of constraints). Note that a new project is not automatically saved, you need to explicitly save it to revert to it in the future (you are warned when closing an unsaved project). You can attach a memo to a project to keep track of its evolution.
     The unique graphical interface makes a detailed examination of the line easy. Operations and possible constraints are reviewed in the Operations tab, the Zoning dialog and the Variant Editor or BOM dialog together with the Edit Product Mix dialog (see item 1). The behavior of the different product models (if defined) is easily examined in the Line Model Summary window. An extensive search facility is available. When there are operations or workstations with multiple operators, the detailed assignment of operations to operators can be examined in the Operators Tab.

4. Adjust constraints if necessary, and return to item 2.

    According to our experience, the very first solution (assignment of operations to workstations) is seldom adopted as the final one. The reason is that the optimizing algorithm has the capacity to find excellent-quality solutions you may not have thought of, by exploiting every opportunity offered by the constraints to supply a well-balanced line. Especially experienced line designers often operate with an implicit set of constraints, some of which may appear so obvious that you fail to specify them explicitly in OptiLine. Since they are not explicit, OptiLine will transgress them if this can make for a better-balanced line.
    Accordingly, the detailed examination of the solution may reveal constraints that may need to be added in order to obtain the perfect line. Typical items include

• Forgotten precedence constraints: OptiLine assigns operation A to a workstation that is after (to the right of) the operation where operation B is assigned, even though B should follow A. Add the precedence A->B in the Operations Tab.
• Forgotten zoning: OptiLine assigns operation A to a workstation that is in fact unable to carry out that operation, due e.g. to a lack of physical space. Assign the operation to a zone in the Zoning dialog , or assign it outright to a given workstation by making it unmovable.
• Forgotten multiple operators: OptiLine assigns operation A to just one operator, even though two or more operators are required to carry it out. Assign the required number of operators in the Operations Tab.
• Forgotten link: OptiLine assigns operations A and B to different workstations, but A and B should be done at the same workstation. Link operation A with B.
• Forgotten fix: OptiLine assigns operation A to the same workstation as B, although B should be alone on its workstation. Make B fixed.
• Forgotten link+fix+unmovable: OptiLine changes the contents of (i.e., the operations assigned to) a workstation that should not be modified. Link all the operations on the workstation together (this will keep them together), fix the resulting link (this will preclude addition of any other operation to the workstation) and make it unmovable (this will fix all the operations to the workstation).
• Forgotten positions (ergonomic constraints): OptiLine assigns operations that require the product to (for instance) be elevated, to a workstation that is known not to elevate the product, or to the same workstation as operations requiring the product not to be elevated. Edit the operation's and (if necessary) workstation's positions.
• Forgotten product model(s): OptiLine assigns to the same workstation long operations that pertain to rare options of the product, leading to unacceptable peak times on products having all of those options. Define a product model with those options, so that the optimization algorithm can attempt to reduce the peak time.

    The fast response time of OptiLine's algorithm allows you to add any constraints deemed necessary, and restart the optimization with the new set of constraints to observe their impact (item 2).