10. Given the following information concerning the design of an assembly line St
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10. Given the following information concerning the design of an assembly line Station Operation Assigned Std. Element Times (seconds) Si S2 S3 S4 S5 34 25, 11 20, 17 34 35 3,4 2.5 A. B. C. D· What is the Cycle Time of this line? What is the line's balance delay? What is the weekly capacity, given 5 days per week and one 8 hour shift per day? If there is a worker at each station, and the average hourly wage for the lie s$150. how much money does the company lose per week due to balance delay? Assume 5 days per week and one 8 hour shift per day E. If you could increase the efficiency of one of the stations to 120% of standard by replacing one of the workers with a more experienced worker, at which station would you place the experienced worker? What impact would this have on your weekly capacity? F. Is it possible to perfeetly balance this line? ExplainExplanation / Answer
Hence cycle time of the line = 35 seconds
= Cycle time x Number of stations – Sum of std. element times
= 5 x 35 - ( 34 + 25.11 + 20.17 + 34 + 35 )
= 175 – 148.28
= 26.72 seconds
Weekly capacity
= Weekly available time / cycle time
= 40 x 3600 / 35
= 4114,28 ( 4114 rounded to nearest whole number )
= Line’s balance delay x weekly capacity
= 26.72 x 4144
= 109926.08 seconds
= 109926.08/ 3600 hour
Average hourly wage = $15
Thus money company loss weekly due to balance delay
= $ 15 x 109926.08/3600
= $ 458 ( rounded to whole number )
Since efficiency of the station will now be 120 % of previous one,
The revised cycle time of station 5 will be = 35/1.2 seconds = 29.16 seconds
It will thus no more be the bottleneck workstation. The bottleneck workstation thus will be station 4 with cycle time 34 seconds.
The revised weekly capacity thus will be = 40 x 3600 /34 = 4235.29 ( 4235 rounded to whole number)
This will result in increase in weekly capacity by = 4235 – 4114 = 121 units
F,It is extremely difficult to perfectly balance a line in which case idle time for each station should be zero. This can be possible only when sum of activities for each workstation be equal to required cycle time. However this is very difficult to achieve in reality.
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