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    Green Grass, Inc.: Operations Management and TQM Layout Planning

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    maria evangelista
    This document contains a problem to calculate cycle time, theoretical minimum, efficiency, and balance delay for an assembly line producing a fertilizer spreader. It provides work element times totaling 244 seconds. It then calculates a cycle time of 90 seconds based on a desired output of 2000 units per week. The theoretical minimum stations is calculated as 3. Idle time is calculated as 26 seconds. Efficiency is calculated as 90.4%. Balance delay is calculated as 9.6%.

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    Green Grass, Inc.: Operations Management and TQM Layout Planning

    Uploaded by

    maria evangelista
    50 views4 pages
    This document contains a problem to calculate cycle time, theoretical minimum, efficiency, and balance delay for an assembly line producing a fertilizer spreader. It provides work element times totaling 244 seconds. It then calculates a cycle time of 90 seconds based on a desired output of 2000 units per week. The theoretical minimum stations is calculated as 3. Idle time is calculated as 26 seconds. Efficiency is calculated as 90.4%. Balance delay is calculated as 9.6%.

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    This document contains a problem to calculate cycle time, theoretical minimum, efficiency, and balance delay for an assembly line producing a fertilizer spreader. It provides work element times totaling 244 seconds. It then calculates a cycle time of 90 seconds based on a desired output of 2000 units per week. The theoretical minimum stations is calculated as 3. Idle time is calculated as 26 seconds. Efficiency is calculated as 90.4%. Balance delay is calculated as 9.6%.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    50 views4 pages

    Green Grass, Inc.: Operations Management and TQM Layout Planning

    Uploaded by

    maria evangelista
    This document contains a problem to calculate cycle time, theoretical minimum, efficiency, and balance delay for an assembly line producing a fertilizer spreader. It provides work element times totaling 244 seconds. It then calculates a cycle time of 90 seconds based on a desired output of 2000 units per week. The theoretical minimum stations is calculated as 3. Idle time is calculated as 26 seconds. Efficiency is calculated as 90.4%. Balance delay is calculated as 9.6%.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 4

    Name: Bautista, Anjolina B.

    Block/Course: BSA 2A

    OPERATIONS MANAGEMENT AND TQM


    LAYOUT PLANNING
    Calculating the Cycle Time, Theoretical Minimum and Efficiency
    Problem for solving:
    Green Grass, Inc., a manufacturer of lawn and garden equipment, is designing an assembly
    line to produce a new fertilizer spreader, the Big Broadcaster. Below are the given work
    elements, time and immediate predecessor data.

    GREEN GRASS, INC.

    Required:

    A. DRAW A PRECEDENCE DIAGRAM.


    B. COMPUTE FOR THE CYCLE TIME.
    First convert the desired output rate (2,000 units) to an hourly rate by dividing the weekly
    output rate by 50 hours per week to get units per hour. Then the cycle time is;

    Cycle Time (in seconds)

    Cycle time, c is the maximum time allowed for work on a unit at each station:
    ✓ Desired output rate, r = 2000/units
    Plant operates 50 hours/week
    r = 2000/50 = 40 units/hour
    seconds
    ✓ Cycle time, c = 1 (3,600 )
    r hour

    ✓ Cycle time, c = 1 (3,600)


    40

    = 90 seconds/unit

    THE CYCLE TIME OF THE LINE IS 90 SECONDS/UNIT

    C. COMPUTE FOR THE THEORETICAL MINIMUM.


    Theoretical minimum (TM) is a benchmark or goal for the smallest number of stations
    possible, where total time required to assemble each unit (the sum of all work element
    standard times is divided by the cycle time. It must be rounded up.

    Theoretical minimum number of workstations

    244 seconds
    = 90 seconds = 2.711 or 3 stations

    THE THEORETICAL MINIMUM NUMBER OF WORKSTATIONS, TM = 3

    D. COMPUTE FOR THE IDLE TIME.


    Idle time is the total unproductive time for all stations in the assembly of each unit.

    Idle time (in seconds)

    ✓ Idle time =
    ✓ Idle time = 3 (90) – 244 = 26 seconds

    THE IDLE TIME IS 26 SECONDS


    E. COMPUTE FOR THE EFFICIENCY.
    Efficiency (%) is the ratio of productive time to total time.

    Efficiency

    244
    Efficiency (%) = (100)
    3 (90)

    Efficiency (%) = 90.37% or 90.4% (rounded off)

    F. COMPUTE FOR THE BALANCE DELAY.


    Balance Delay (%) is the amount by which efficiency falls short of 100%.
    Balance Delay (%) = 100 – Efficiency
    Balance Delay (%) = 100 – 90.4

    Balance Delay (%) = 9.6

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