Layout (revised) A car manufacturer is planning to install an assembly line for

Question

Layout (revised)

A car manufacturer is planning to install an assembly line for a new model of car, and the engineering team has been asked to balance the process, given the following task times and precedence relationships. Assume a 600-minute working day and a desired output rate of 50 cars per day.

3. Assign the tasks to workstations according to the greatest number of following tasks. In case of a
tie, use the tiebreaker of assigning the task with the longest processing time rst. [12 marks]
4. Draw the product layout for the car assembly process based on the task assignment results. [3
marks]
5. Determine the percentage of idle time and hence the e¢ ciency of the product layout. [5 marks]

Thanks very much

Task Time (minutes) Immediate Followers a 4 b,c b 6 d c 3 f d 3 e e 2 g f 10 e g 8 h h 4 -

Explanation / Answer

Given the data is as follows

Assume a 600-minute working day and a desired output rate of 50 cars per day

Calculating Cycle Time

Cycle Time = (production time per day) / (output per day)

Cycle Time = (600) / (50) = 12 min

Calculating theoretical Minimum Number of workstations

Minimum number of work station = (Sum of total Task Time) / (cycle time)

Minimum number of workstation = 40 / 12 = 3.33 = 3 workstation rounded off

Efficiency of the Line Balance

Efficiency of line balance = (Sum of All task time) / ((Actual number of work station) x (Cycle time))

Efficiency = 40 / (3*12) = 1.11

Sequential Relationship among tasks and predecessor diagram

Please note given data have issues as the effeciency is higher than 100% please recheck the data to do the line balancing again

Please note given data have issues as the effeciency is higher than 100% please recheck the data to do the line balancing again

Station Eligible task Assigned task task time (min) Cumulative time (min) Idle Time (Min) 1 a a 4 4 8 2 b,c b 6 6 6 2 c,d c 3 9 3 2 d,f,e d 3 12 0 3 f,e f 10 10 2 3 e e 2 12 0

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