Chapter 16 Homework Line Balancing Problems
Instructions: Work the three problems from the attached file (Line Balancing) above labeled Chapter 16 Facility Layout Homework Problems. Formulas can be completed in Excel if it helps for computation purposes. Follow the 6 Steps: (example)
Step 1: Identify tasks and immediate predecessors (perfume spray filling and packaging line example in Table 16.1
Step 2: Determine output rate of final item (for example, 600 bottles per hour with 8 hours per shift).
Step 3: Determine cycle time (the amount of time each workstation is allowed to complete its tasks).
The throughput or capacity of this process is limited by the bottleneck task (the longest task in a process), which can be calculated as follows:
Step 4: Compute the theoretical minimum number of stations (that is, the number of stations needed to achieve 100% efficiency where every available second is used).
Note that you should always round up when calculating the number of workstations.
Step 5: Assign tasks to workstations.
Start at the first station and choose the longest eligible task following precedence relationships (that is, A must precede B, G must follow both E and F, and so on; see Table 16.2). Continue adding the longest eligible task that fits without going over the desired cycle time. Once no additional tasks can be added within the desired cycle time, assign the next task to the following workstation until finished.
(Table 16.2) Example – there should be a Line Balance table for each problem
Table 16.2 Perfume and Packaging Line Balancing Example: Assign Tasks to Workstations
Step 6: Compute efficiency and balance delay. The percent efficiency is the ratio of total task times divided by the number of workstations times the largest assigned cycle time (6 seconds for workstation 4).
Balance delay is the percentage by which the assembly line falls short of 100%.
Balance delay = 100% – 86.1% = 13.9%
Of course, Step 1 is provided for you.
- The maker of the world-famous Chocolate Chip Cookies needs to design a product layout for a new product, Mint Chocolate Chip. The company plans to use this new production line eight hours a day in order to meet projected demand of 1,440 cases per day. The following table describes the tasks involved in the production of a case of Mint Chocolate Chip Cookies.
| Task | Time(secs) | Immediate Predecessor |
| u | 4 | none |
| v | 14 | u |
| w | 12 | v |
| x | 12 | v |
| y | 6 | w |
| z | 8 | x,y |
- A company needs to rebalance a product layout for producing new plastic license plates. They plan to use the assembly line six hours a day in order to meet projected demand of 2,160 license plates each day. The following table describes the tasks involved in the production of this product:
| Task | Time(secs) | Immediate Predecessor |
| a | 3 | none |
| b | 4 | none |
| c | 5 | a,b |
| d | 7 | none |
| e | 9 | c,d |
- The XYX company need to line balance the new production line for their snap together tablet. The production line will run seven hours a day in order to meet projected demand of 500 units per day. The following table describes the tasks involved in the production of this product:
| Task | Task Time(seconds) |
Immediate Predecessor |
||
| A | 45 | – | ||
| B | 11 | A | ||
| C | 9 | B | ||
| D | 50 | – | ||
| E | 26 | D | ||
| F | 11 | E | ||
| G | 12 | C | ||
| H | 10 | C | ||
| I | 9 | F, G, H | ||
| J | 10 | I | ||
193
What Students Are Saying About Us
.......... Customer ID: 12*** | Rating: ⭐⭐⭐⭐⭐"Honestly, I was afraid to send my paper to you, but splendidwritings.com proved they are a trustworthy service. My essay was done in less than a day, and I received a brilliant piece. I didn’t even believe it was my essay at first 🙂 Great job, thank you!"
.......... Customer ID: 14***| Rating: ⭐⭐⭐⭐⭐
"The company has some nice prices and good content. I ordered a term paper here and got a very good one. I'll keep ordering from this website."
