Kiko Teddy Bear is a manufacturer of stuffed teddy bears. Kiko would like to be

Question

Kiko Teddy Bear is a manufacturer of stuffed teddy bears. Kiko would like to be able to produce 40 teddy bears per hour on its assembly line. Use the following information provided in the table below to answer the following.

                                                Immediate

Task    Task Description         Predecessor     Task Time (sec)

A      Cut pattern                        -                              90

B      Sew cloth                         A                            75

C      Stuff bear                         B                            50

D      Glue on eyes                    C                            20

E       Glue on nose                    C                            15

F       Sew on mouth                  C                            35

G      Attach mfr. label              B                            15

H      Inspect and pack         D,E,F,G                      40

                                                                        ? = 340 seconds

e. What is the efficiency and balance delay?

f. Which task is the bottleneck?  

  Which workstation is the bottleneck?

g. Compute the maximum output? (Assume 8 hour day)

  Compute the minimum output? (Assume 8 hour day)

Explanation / Answer

b) Cycle Time= 60*60/40 = 90 sec

c) Minimum number of workstations= sum of total task times / cycle time

                        = 340/90 = 3.78 = 4 workstations

Task Table

Task

Task time

Precedence

A

90

-

B

75

A

C

50

B

D

20

C

E

15

C

F

35

C

G

15

B

H

40

D,E,F,G

The total station time is nothing but the cycle time. So, total station time of each station is 90 secs.

In order of longest task time, order of task execution:

A>B>C>H>F>D>E>G

               Workstation 1:

                        First task =A

                        Time left= 90-90 = 0 secs

                       

So, workstation 1: A

Workstation 2:

                        First task =B

                        Time left= 90-75 = 25 sec

                       

So, workstation 2: B

Workstation 3:

                        First task=C

                        Time left= 90-50= 40 sec

                        Second task=F

                        Time left=40-35 = 5 sec

                       

So, workstation 3: C->F

Workstation 4:

                        First task= D

                        Time left=90 – 20= 70 secs

                        Second task=E

                        Time left=70-15 = 55 sec

                        Third task=G

                        Time left=55-15 = 40 sec

                        Fourth task=H

                        Time left=40-40 = 0 sec

So, workstation 4: D->E->G->H

Work Station

Tasks

Workstation time

Idle Time

1

A

90

0

2

B

75

15

3

C->F

85

5

4

D->E->G->H

90

0

e) Total idle time or balance delay = 0+15+5+0 = 20 sec

Efficiency with 4 workstations = (sum of all tasks) / (no of workstations * Cycle time)

        = (340)/ (4*90) = 0.944 or 94.4 %

f) Bottleneck task = task which takes most amount of time = A

Bottleneck workstation= workstation with most idle time =Workstation 2

g) Minimum cycle time = longest task time = 90 secs

Maximum cycle time = sum of all task times = 340 secs

Maximum output = 8*60*60/90 = 320 units

Minimum output = 8*60*60/340 = 84.7 units

Task

Task time

Precedence

A

90

-

B

75

A

C

50

B

D

20

C

E

15

C

F

35

C

G

15

B

H

40

D,E,F,G

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