QUAN4640

Chapter 8
(4)

Peter's Paper Clips uses a three-stage production process: cutting wire to prescribed
lengths, inner bending, and outer bending. The cutting process can produce at a rate of
150 pieces per minute; inner bending, 140 pieces per minute, and outer bending, 110
pieces per minute. Determine the hourly capacity of each process stage and the number
of machines needed to meet an output rate of 20,000 units per hour. How does facility
layout impact your numerical analysis and process efficiency? Explain.

(5)

An assembly line with 30 activities is to be balanced. The total amount of time to

complete all 30 activities is 42 minutes. The longest activity takes 2.4 minutes and the
shortest takes .3 minutes. The line will operate for 480 minutes per day.
a. What are the maximum and minimum cycle times?

b. What output rate will be achieved by each of those cycle times?

(6)

In Problem 5, suppose the line is balanced using 10 workstations and a finished product
(unit) can be produced every 4.2 minutes.
a. What is the production rate in units per day?

b. What is the assembly line efficiency?

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(7)

A small assembly line for the assembly of power steering pumps needs to be balanced.
Exhibit 8.11 in the text is the precedence diagram. The cycle time is determined to be
1.5 minutes. How would the line be balanced using
a. Longest (largest) processing time first rule?
Station
1
2
3

Tasks

Total time

Idle Time

Total

(9)

You have been asked to set up an assembly line to assemble a computer mouse. The
precedence network is shown below; task times in minutes are given in parentheses. There are
480 minutes of assembly time per shift and the company operates one shift each day. The
required output rate is forecasted to be 60 units per shift.

Task 1 (4)

Task 5 (6)

Task 2 (5)
Task 8 (8)

Task 3 (1)

Task 4 (2)

Task 6 (3)

Task 7 (3)

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Work Station

Assigned Tasks

Total Time

Idle Time

A
B
C
D
E
F

(a).

Complete the worksheet using the longest processing time rule.

(b)

What is the assembly line efficiency?

(c)

Is your assembly line balance solution good or bad? What criteria do you used to make
this assessment? Explain.

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(10)

Balance the assembly line in Exhibit 8.12 for (a) a shift output of 60 pieces and (b) a shift output
of 40 pieces. Assume an eight-hour shift, and use the rule, choose the assignable task with the
longest processing time. Compute the line efficiency for each case.
For an output of 60 pieces/shift, cycle time = 8(60)/60 = 8 minutes/unit. You need to go
over the cycle time calculation carefully.
Work station
1
2
3
4
5
6
7

Tasks Total Time

Total

Idle Time