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The document describes a problem involving the design of a manual assembly line to meet an annual demand of 100,000 units. It provides information on the line's operating hours and work content time. It then asks to determine the average hourly production rate, cycle time, theoretical minimum number of workers, and actual number of workers required. Another problem involves precedence relationships and element times for a toy model to determine the theoretical minimum number of workstations and balance delay.

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Bandi Kumarreddy
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29 views4 pages

Solutions

The document describes a problem involving the design of a manual assembly line to meet an annual demand of 100,000 units. It provides information on the line's operating hours and work content time. It then asks to determine the average hourly production rate, cycle time, theoretical minimum number of workers, and actual number of workers required. Another problem involves precedence relationships and element times for a toy model to determine the theoretical minimum number of workstations and balance delay.

Uploaded by

Bandi Kumarreddy
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
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2.

A plastic extrusion plant will be built to produce 30 million meters of plastic extrusions per
year. The plant will run three 8-hour shifts per day, 360 days per year. For planning purposes,
the average run length = 3000 meters of extruded plastic. The average changeover time between
runs = 2.5 hr, and average extrusion speed = 15 m/min. Assume scrap rate = 1%, and average
uptime proportion per extrusion machine = 95% during run time. Uptime proportion during
changeover is assumed to be 100%. How many machines will be required to meet demand?

Solution:
30 , 000 , 000 m/ yr
Production: WL = 15(60 )m/hr(1−0 . 01) = 33,670.0 hr/yr
AT = 360(3)(8)(0.95) = 8208 hr/yr.
30 , 000 , 000 m/ yr
Changeover: number runs/yr = 3000 m/run = 10,000 runs/yr = 10,000 changeovers/yr
WL = 10,000(2.5) = 25,000 hr/yr
AT = 360(3)(8) = 8640 hr/yr per machine
33 , 670 25 , 000
+
n = 8208 8640 = 4.102 + 2.894 = 6.995  7 machines.

1. A manual assembly line must be designed for a product with annual demand = 100,000
units. The line will operate 50 wks/year, 5 shifts/wk, and 7.5 hr/shift. Work units will be
attached to a continuously moving conveyor. Work content time = 42.0 min. Assume line
efficiency = 0.96, balance delay = 0.08, and repositioning time = 6 sec. Determine
a) average hourly production rate to meet demand,
b) cycle time,
c) theoretical minimum number of workers required on the line,
d) how many workers will actually be required?

Solution:

(a) Rp = = 53.33 pc/hr

(b) Tc = = 1.08 min,

(c) w* = Minimum Integer  = 38.89  39 workers


(d) Ts = 1.08 - 0.1 = 0.98 min
w = Minimum Integer  = 46.58  47 workers

15.11. The table below defines the precedence relationships and element times for a new model toy. (a)
Construct the precedence diagram for this job. (b) If the ideal cycle time = 1.1 min. repositioning time = 0.1
min, and uptime proportion is assumed to be 1.0, what is the theoretical minimum number of workstations
required to minimize the balance delay under the assumption that there will be one worker per station? (c)
Use the largest candidate rule to assign work elements to stations. (d) Compute the balance delay for your
solution.
Work element Te (min) Immediate predecessors
1 0.5 -
2 0.3 1
3 0.8 1
4 0.2 2
5 0.1 2
6 0.6 3
7 0.4 4,5
8 0.5 3,5
9 0.3 7,8
10 0.6 6,9
Solution: (a) Precedence diagram:

0.2
0.3 4 0.4
2 7

0.1 0.3
5 0.5
0.5 9
8
1 0.6
0.8 10
3 0.6
6

(b) Ts = Tc - Tr = 1.1 - 0.1 = 1.0 min

With M = 1.0, n = w = Minimum Integer  = 4.3, Use n = 5 stations

(c) Line balancing solution using the largest candidate rule.


List of elements by Te value Allocation of elements to stations
Element Te (min) Predecessors Station Element Te  Te
3 0.8 1 1 1 0.5 min
6 0.6 3 2 0.3 min
10 0.6 6, 9 4 0.2 min 1.0 min
1 0.5 - 2 3 0.8 min
8 0.5 3, 5 5 0.1 min 0.9 min
7 0.4 4, 5 3 6 0.6 min
2 0.3 1 7 0.4 min 1.0 min
9 0.3 7, 8 4 8 0.5 min
4 0.2 2 9 0.3 min 0.8 min
5 0.1 2 5 10 0.6 min 0.6 min
4.3 min total
5(1.0)−4 .3
(d) Balance delay d = 5(1.0) = 0.14 = 14%

15.12Solve the previous problem using the Kilbridge and Wester method in part (c).
Solution: (a) Precedence diagram same as in Problem 15.11.

(b) Same as in Problem 15.11: n = 5 stations.

(c) Line balancing solution using the Kilbridge & Wester method:

List of elements by precedence columns Allocation of elements to stations


Element Te (min) Column Station Element Te  Te
1 0.5 I 1 1 0.5 min
2 0.3 II 2 0.3 min
3 0.8 II,III 4 0.2 min 1.0 min
4 0.2 III 2 3 0.8 min
5 0.1 III 5 0.1 min 0.9 min
6 0.6 III,IV 3 6 0.6 min
7 0.4 IV 7 0.4 min 1.0 min
8 0.5 IV 4 8 0.5 min
9 0.3 V 9 0.3 min 0.8 min
10 0.6 VI 5 10 0.6 min 0.6 min
4.3 min total
(d) Same as in Problem 15.11: d = 0.14 = 14%

15.13. Solve the previous problem using the ranked positional weights method in part (c).
Solution: (a) Precedence diagram same as in Problem 15.11.

(b) Same as in Problem 15.11: n = 5 stations.

(c) Line balancing solution using the Kilbridge & Wester method:

Elements by ranked positional weights Allocation of elements to stations


Element Te (min) RPW Station Element Te  Te
1 0.5 4.3 1 1 0.5 min
3 0.8 2.8 2 0.3 min
2 0.3 2.4 5 0.1 min 0.9 min
5 0.1 1.9 2 3 0.8 min
4 0.2 1.5 4 0.2 min 1.0 min
8 0.5 1.4 3 8 0.5 min
7 0.4 1.3 7 0.4 min 0.9 min
6 0.6 1.2 4 6 0.6 min
9 0.3 0.9 9 0.3 min 0.9 min
10 0.6 0.6 5 10 0.6 min 0.6 min
4.3 min total
(d) Same as in Problem 15.11: d = 0.14 = 14%

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