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Question 9.1
Movements = (4 8) + (9 7) + (7 4) + (6 3) + (8 2) + (10 6) = 32 + 63 + 28 + 18 + 16 + 60 = 217 (in 100s) = 21,700 Cost = 21,700 $1 = $21,700
Question 9.2 (a) Plan A movements = (20x6)+(12x18)+(8x2)+(6x4)+(10x2)+(4x18) = 120+216+16+24+20+72 = 468 (in 100s) = 46,800 Cost =46,800 x 0.50 = $23,400.00
(b) Plan B movements = (20x6)+(8x18)+(12x2)+(10x4)+(6x2)+(4x18) = 120+144+24+40+12+72 = 412 (in 100s) = 41,200 Cost =41,200 x 0.50 = $20,600.00
(c) Plan C movements = (20x6)+(10x18)+(6x2)+(8x4)+(12x2)+(4x18) = 120+180+12+32+24+72 = 440 (in 100s) = 44,000 Cost =44,000 x 0.50 = $22,000.00
Question 9.10 (a) Takt time Minutes available per day/Units demanded per day 420/250 1.68 minutes (1.1 4.76 1.1 5 1.7 3.1 1.0)/1.68 8.0/1.68
(c) The cleaning operation is substantially longer than the others so it warrants special consideration to ensure that a smooth flow can be maintained. A machine constrained task or lack of cross-training may suggest that more traditional assembly line balancing techniques be used.
Question 9.11
(60)(60 sec) 180 PLAs 3,600 = 20 seconds per PLA 180 task time cycle time 60 =3 20
(c) Yes, it is feasible. Station 1 with A and C; Station 2 with B and D; and Station 3 with E.
BUS P301:01
(b) Station 1 gets A, G, and B and has 0.5 minutes left over. Station 2 gets C, D, and E, with no time left over. Station 3 gets F, H, I, and J and has 0.5 minutes left over. Improvements in efficiency would seem impossible. The times are in 0.5 minute increments and cant be sub-divided to achieve exact balance. Total of 1 minute of idle time/cycle. (c) If stations 1 and 3 each had 0.5 minute more work to do, the line would be 100% efficient; perhaps support tasks could be assigned to them.
Time Station Task (minutes) 1 A 5 G 3 B 1.5 2 C 3 D 4 E 3 3 F 2 H 3.5 I 2 J 2 Time Left (minutes) 5 2 0.5 7 3 0 8 4.5 2.5 0.5 Ready Tasks B, G B C, E E, D E F H I J
Summary Statistics Cycle time Time allocated (cyc sta) Time needed (sum task) Idle time (allocated-needed) Efficiency (needed/allocated) Balance delay (1-efficiency)
(a)
(b)
24hr 96 units
60min hr
15min
(c)
1 unit 10 min
60 min hr
(d)
BUS P301:01
(e) Efficiency
Time needed per unit Time allocated per unit Total task time (Cycle time) (Number of stations) 50 (10)(6) 50 60 .8333, or 83.33%
(g) Best assignment is shown in part (a); efficiency is shown in part (e) (i.e., 83.33%)
BUS P301:01