1. Determine load of a workstation if its lot size =25 and set up = 1.5 hours and run time = 0.

2 hours

Load 0.26 load= setup time/ lot size + run time

2. If workpieces are completed in a workstation in a batch of 100 and setup time is 2 minutes and run time is 0.2 minute per u

a. Total run time 20 min

Production rate 4.55 units/min
272.73 units/ hour

b. Batch size is halved 50

Total Run time 10 min

Production Rate 4.17 units/min

250.00 units/ hour
s and run time is 0.2 minute per unit, a. what is the production rate? b. If the batch size is halved, what’s its impact in production rate?
mpact in production rate?
 3. Consider a production sequence: grinding→milling→drilling taking 15 mins, 12 mins and 15 mins respectively for every u
production rate per day? b. Identify bottleneck and non-bottleneck work stations? c. What is your observation on WIP in this
rate? f. If you are able to save 2 minutes in workstation 3, is there an impact in production rate? g. If you are able to save 2
change in production rate or utilization or WIP? i. What is the production lead time when the process batch size and transfer b
tran

a Total time taken for production o= 15+12+1 42

Total working hours in the factor = 8hrs = 8 480

Max possible production rate = 480/42 = 11.42 , i.e. 11 units per day
11

b Bottleneck workstations are grinding and drilling .

Non - bottleneck workstation is milling .

c The situation is worse in this set-up . We are achieving only 27.5% efficiency compared to the maximum possible pr

d Firstly , it is rather impossible to achieve maximum production rate. Addition of equipments or overtime working ho

e If 2 min saved on W1 , i.e. grinding = 15 -2 = 13 min

Therfore , total time taken = 40 min

Production rate = 480/ 40 = 12 units .

Only one unit is increased in production .

f Same scenario will happen as in the above case (E)

g When two min saved on both W1 and W3 , then total time taken in producing one unit = 38 min

Thus , new production rate = 480 / 38 = 12.6 , i.e. we can reach upto 13 units maximum .

h If the milling is done beforehand than other processes , it can optimise the time taken by other workstations to deli

i Process batch size = 1500

Transfer batch size = 1500

Production lead time = pre-processing + processing + post-processing time

= 1500*15 + 1500*12 + 1500*15

= 1500*42

= 63000 min

= 1050 hours

New process batch size = 500

New transfer batch size = 100

New Production lead time = 100* 15 + 500*12 +100*15

= 1500 + 6000 +1500

= 9000 min = 150 hrs

 mins respectively for every unit of the product. Daily demand of this product is 40 units. Assume that the factory works 8 hours per day. a
ur observation on WIP in this scenario? d. What should be done to meet the demand? e. If you are able to save 2 minutes in workstation 1
e? g. If you are able to save 2 minutes in both workstation 1 and 3, is there an impact in production rate? h. If the sequence is milling→grin
ocess batch size and transfer batch size is 1500? What is the production lead time when the process batch size is made variable in non-bott
transfer batch size is 100?

d to the maximum possible production rate which is very poor. 27.50%

ments or overtime working hours or reducing/ optimising the time spent on various workstations is also required when dealing with such s

by other workstations to deliver their output . This can be a good optimising solution for increasing output rate at other workstations .
ctory works 8 hours per day. a. What is the maximum possible
ave 2 minutes in workstation 1, is there an impact in production
f the sequence is milling→grinding →drilling, will there be any
ze is made variable in non-bottleneck split into 500, 500, 500 and

uired when dealing with such situations .

rate at other workstations .

 4. A producer of inkjet printers is planning to add a new line of printers, and you have been asked to balance the process, giv
possible. Task Length (min) Immediate Predecessor a 0.2 - b 0.4 a c 0.3 - d 1.3 b,c e 0.1 - f 0.8 e g 0.3 d,f h 1.2 g a. Draw prece
any using greatest positional weight c. Find idle time perce

Activity Time Precedence Remaining time

1 a 0.2 3.4
b 0.4 a 3.2
c 0.3 3.1
d 1.3 b,c 2.8
e 0.1 2.4
f 0.8 e 2.3
g 0.3 d,f 1.5
h 1.2 g 1.2 4
4.6

Station Task Task time Remaining in cycle time

1 a 0.2 1.1
b 0.4 0.7
c 0.3 0.4
e 0.1 0.3
Idle time 0.3
2 d 1.3 0
Idle time 0
3 f 0.8 0.5
g 0.3 0.2
Idle time 0.2

4 h 1.2 0.1
Idle time 0.1

Total Idle 0.6

en asked to balance the process, given the following task times and precedence relationships. Assume that cycle time is to be the minimum
0.8 e g 0.3 d,f h 1.2 g a. Draw precedence diagram b. Assign tasks to stations in order of greatest number of following tasks. Break the tie i
tional weight c. Find idle time percentage d. Find the efficiency of the line

Desired output rate

Total task time 4.6 mins

Highest time taken by 1.3

No. of work stations = 3.54 4

Idle time = Idle time per cycle / (N * Cycle time) * 100

Idle time 0.115385

%age idle time 11.54%

Efficiency 88.46%
ycle time is to be the minimum
following tasks. Break the tie if
 Rough
c
1.3
1.1
0.7
0.4

1a b c

2d

3f g

4h
e
1.3
1.1
0.7
0.1

e 0.3

0.2

0.1

0.6
Determine the placement of departments for a newly designed facility that will minimize total transportation costs using the d

In decending order Highest Loaction

Locations 2 and 4 have the highest interdepar A (2)
Departments Trips So, we put them close to C
2-4 90 Considering they are placed at A & B
1-4 80
3-4 55 2nd Highest Location
2-3 40 Locations 1 and 4 have the second highest interdepartmental work
1-3 20 So, we put them at B & C
1-2 10
3rd
Department D should be located at the last location
ortation costs using the data in the following tables. Assume that the reverse distances are the same. The locations are shown in the grid.

What is the total cost after allocation?

Allocation Calculating Transportation cost

B (4) C (1) DepartmenTrips Distance Total Cost Total Cost
D (3) 2-4 90 A-B = 40 3600 distance*trips*$1
1-4 80 B-C = 40 3200
3-4 55 B-D = 50 2750
2-3 40 A-D = 70 2800
erdepartmental work 1-3 20 C-D = 60 1200
1-2 10 A-C = 80 800
14350
cations are shown in the grid. Use a cost of $1 per trip yard.