EOM 19 20 Trim B T10 - Tutorial PDF

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Assembly Line Balancing Tutorial 1

Caltech has a projected customer demand that averages 480 items per working day. Caltech's production has the following task times assigned to each station: STATION 1 40 s

STATION 2 25 s

STATION 3 30 s

STATION 4 30 s

a) What is the Cycle Time and the Hourly Production Rate? b) What should the Cycle Time be to produce the 480 units per day if the production line works 7.5 hours per day? c) If the line runs for 7.5 hours per day with a Cycle Time of 40 s what will be the result? d) How should management solve this problem? 2

Considering the data for each workstation, determine: a) Which is the bottleneck workstation? b) What is the Hourly Production Rate? c) If each worker makes £11 per hour what is the labour cost per product? WORKSTATION 1 2 3 4

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TIME [s] 40 27 30 35 30 40 63

PREDECESSORS A A, D B D C, E, F

Snack-You-Like have signed a contract to deliver a minimum of 2,000 and a maximum of 4,000 sandwiches to each home game of Caledonian FC. Even 2,000 is more than double its sales day. The sandwiches need to be made fresh for each game. To make this many sandwiches it will need to use an assembly line. Following are the precedence relationships and estimates of the time required for each step. TASK A B C D E F G

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TASK TIMES [s] 40, 90 120 100 40, 40

Considering the data for the tasks in the table below: a) Draw the Precedence Diagram. b) Assuming a Cycle Time of 70 s balance the Assembly Line using the longest task time rule. c) ow many products can be built if the Assembly Line is operational for 7.25 hours per day? TASK A B C D E F G

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TASK ASSIGNED A, B C D E, F

DESCRIPTION Spread margarine Add green pepper Add lettuce Add meat Add cheese Add tomato Wrap sandwich

TIME [s] 15 10 5 7 6 5 10

PREDECESSOR A A A A A B,C,D,E,F

EOM_19_20_TrimB_T10

Because most of the workers will be students the number of hours the Assembly Line can work is variable. Snack-You-Like calculate that they will have 9 hours of actual production time. a) What Cycle Time is required to deliver 4,000 sandwiches using the 9 hours of production time? b) Devise a plan that would allow Snack-You-Like to make 4,000 sandwiches. Include in this plan the Cycle Time, the number of Assembly Lines and the hours worked. Remember that on some days it may only have to make 2,000 sandwiches. c) Balance the line using the Cycle Time from part b and the longest task time rule.

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Corstorphine Industrial Ltd have balanced their production line as shown below STATION 1 2 3 4 5 a) b) c) d)

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TASKS A, B C D, E F G

TIMES [s] 40, 30 80 40, 40 60 50

Which is/are the bottleneck station(s)? Assuming an 8 hour working day, what is the maximum output? What is the Idle Time? If each worker makes £6.50 per hour what is the labour cost per unit? If 2 people were assigned to stations 2 and 3 what would the maximum daily output become? What would be the labour cost per unit?

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