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Miscellaneous Plastic (Plastic Scoop) : F E D C B A

This document analyzes the production processes and efficiency of four production lines that manufacture different plastic products. It calculates key metrics like cycle time, minimum number of work stations, line efficiency, idle time, and balance delay for each production line. The production lines range from 5 to 6 work stations and have line efficiencies from 81-97%. Idle time and balance delay vary across the different processes.

Uploaded by

Prince Shan
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
68 views

Miscellaneous Plastic (Plastic Scoop) : F E D C B A

This document analyzes the production processes and efficiency of four production lines that manufacture different plastic products. It calculates key metrics like cycle time, minimum number of work stations, line efficiency, idle time, and balance delay for each production line. The production lines range from 5 to 6 work stations and have line efficiencies from 81-97%. Idle time and balance delay vary across the different processes.

Uploaded by

Prince Shan
Copyright
© © All Rights Reserved
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Miscellaneous Plastic (Plastic scoop)

3s

18s

TASK
A
B
C
D
E
F

TASK
TIME
(seconds)
3
8
12
15
12
10

12s

15s

12s

10s

PREDECESSOR / TASKS
THAT MUST PRECEDE
A
B
C
D
E

TASK DESCRIPTION
Insert raw material
Material inject to mold
Product produce
Cutting and cleaning
QC checking
Packaging

The time for a process is about 60 seconds and the production time is 480 minutes per
day.
Daily production rate is 2800

Cycle time (CT)

CT = Available Time Period (AT)


Output Units required / Period
CT= 480 min x 60 sec
2800
CT= 10.29 seconds / unit

Minimum number of work station

Minimum No Workstation= total process time


Cycle time
Minimum No Workstation= 60 sec
10.29 sec / unit
Minimum No Workstation= 5.8 = 6 (round off)

Efficiency of the line


Line efficiency= Total workstation time
Cycle time x no. of workstation
Line efficiency= 60
2.88 x 6
Line efficiency= 0.972
Line efficiency= 97.2%

Work station according to the balanced line


3s

18s

12s

15s

12s

10s

IDLE TIME
Idle time= [( num of work station)( cycle time)] total workstation time
= [(6) x ( 10.29)] 60
= 1.74

Idle time % = (total idle time / cycle time)


= (1.74 / 10.29) x 100
= 16.91%

BALANCE DELAY (BD) = (total idle time / total workstation time) x 100
BD = (1.74 / 60) x 100
BD = 2.9%

Chemical Product (normal bottle)


16s

14s

50s

55s

D
20s

TASK
A
B
C
D
E
F
G
H
I
J

17s

17s

17s

13s

TASK
TIME
(seconds)
50
16
14
55
20
17
17
17
13
14

14s

PREDECESSOR / TASKS THAT


MUST PRECEDE
A
B
C,F
A
E
H
I
J

TASK DESCRIPTION
Insert raw material
Material inject to mold
Product produce (bottle)
Cutting and cleaning
Product produce (bottle cap)
Cutting and cleaning
Insert raw material
Material inject to mold
Product produce ( insert )
Packaging

The time for a process is about 250 seconds and the production time is 480 minutes per
day.
Daily production rate is 420

Cycle time (CT)

CT = Available Time Period (AT)


Output Units required / Period
CT= 480 min x 60 sec
420
CT= 68.57 seconds / unit

Minimum number of work station

Minimum No Workstation= total process time


Cycle time
Minimum No Workstation= 250 sec
68.57 sec / unit
Minimum No Workstation= 3.6 = 4 (round off)

Efficiency of the line


Line efficiency= Total workstation time
Cycle time x no. of workstation
Line efficiency= 250
68.57 x 4
Line efficiency= 0.912
Line efficiency= 91.2%

Work station according to the balanced line

16s

14s

50s

55s

D
20s

14s

17s

17s

17s

13s

IDLE TIME
Idle time= [( num of work station)( cycle time)] total workstation time
= [(4) x (68.57)] 250
= 24.28

Idle time % = (total idle time / cycle time)


= (24.28 / 68.57) x 100
= 35.39%

BALANCE DELAY (BD) = (total idle time / total workstation time) x 100
BD = (24.28 / 250) x 100
BD = 9.71%

Pharmaceuticals Products (bottles)

54s

G H

TASK
A
B
C
D
E
F
G
H

TASK
TIME
(seconds)
54
24
36
12
18
24
42
66

24s

36s

12s

18s

PREDECESSOR / TASKS THAT


MUST PRECEDE
A
B
A
D
C, E
F
G

24s

42s

66s

TASK DESCRIPTION
Insert raw material
Material inject to mold
Product produce (bottle)
Material inject to mold
Product produce (bottle cap)
Cutting and cleaning
Checking (QC)
Packaging

The time for a process is about 276 seconds and the production time is 440 minutes per
day.
Daily production rate is 400

Cycle time (CT)

CT = Available Time Period (AT)


Output Units required / Period
CT= 440 min x 60 sec
400
CT= 66 seconds / unit

Minimum number of work station

Minimum No Workstation= total process time


Cycle time
Minimum No Workstation= 276 sec
66 sec / unit
Minimum No Workstation= 4.2 = 5 (round off)

Efficiency of the line


Line efficiency= Total workstation time
Cycle time x no. of workstation
Line efficiency= 276
66 x 5
Line efficiency= 0.836
Line efficiency= 83.6%

Work station according to the balanced line

54s

G H

24s

36s

12s

18s

24s

42s

IDLE TIME
Idle time= [( num of work station)( cycle time)] total workstation time
= [(5) x (66)] 276
= 54

Idle time % = (total idle time / cycle time)


= (54 / 66) x 100
= 81.81%

BALANCE DELAY (BD) = (total idle time / total workstation time) x 100
BD = (54 / 276) x 100
BD = 19.56%

66s

Household Product (Bottle Spray)

40s
D
H

30s

20s

40s

6s

25s
C

50s

15s
G

TASK
A
B
C
D
E
F
G
H
I

TASK
TIME
(seconds)
40
30
50
40
6
25
15
20
18

PREDECESSOR / TASKS THAT


MUST PRECEDE
A
A
B
B
C
C
D,E
F,G

18s

TASK DESCRIPTION
Insert raw material
Material inject to mold
Material inject to mold
Product produce (bottle)
Cutting and cleaning
Product produce (spray cap)
Checking (QC)
Packaging
Packaging

The time for a process is about 244 seconds and the production time is 440 minutes per
day.
Daily production rate is 400

Cycle time (CT)

CT = Available Time Period (AT)


Output Units required / Period
CT= 480 min x 60 sec
480
CT= 60 seconds / unit

Minimum number of work station

Minimum No Workstation= total process time


Cycle time
Minimum No Workstation= 244 sec
60 sec / unit
Minimum No Workstation= 4.1 = 5 (round off)

Efficiency of the line


Line efficiency= Total workstation time
Cycle time x no. of workstation
Line efficiency= 244
60 x 5
Line efficiency= 0.813
Line efficiency= 81.3%

Work station according to the balanced line

40s
D
H

30s

20s

40s

6s

25s
C

50s

15s
G

18s

IDLE TIME
Idle time= [( num of work station)( cycle time)] total workstation time
= [(5) x (60)] 244
= 56

Idle time % = (total idle time / cycle time)


= (56 / 60) x 100
= 93.33%

BALANCE DELAY (BD) = (total idle time / total workstation time) x 100
BD = (56 / 244) x 100
BD = 22.95%

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