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Exercises On Line Balancing

This document contains 4 exercises related to line balancing for manufacturing processes. The first exercise provides task times and precedence relationships for balancing a pencil sharpener assembly line. The second exercise gives the same information for an assembly operation to produce 240 units per day. The third exercise provides data for balancing a toy monster truck assembly line to produce 600 units per day. The fourth exercise gives task information for balancing a computer cabinet assembly line. Each exercise asks questions about drawing precedence diagrams, calculating cycle times and workstation requirements to meet production goals.

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Himanshu Sharma
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256 views

Exercises On Line Balancing

This document contains 4 exercises related to line balancing for manufacturing processes. The first exercise provides task times and precedence relationships for balancing a pencil sharpener assembly line. The second exercise gives the same information for an assembly operation to produce 240 units per day. The third exercise provides data for balancing a toy monster truck assembly line to produce 600 units per day. The fourth exercise gives task information for balancing a computer cabinet assembly line. Each exercise asks questions about drawing precedence diagrams, calculating cycle times and workstation requirements to meet production goals.

Uploaded by

Himanshu Sharma
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Exercises on Line Balancing

1. A large manufacturer of pencil sharpeners is planning to add a new line of sharpeners and
you have been asked to balance the process, given the following task times and
precedence relationships. Assume that cycle time is to be the minimum possible.

Task Length Immediate


(minutes) Follower
A 0.2 B

B 0.4 D

C 0.3 D

D 1.3 G

E 0.1 F

F 0.8 G

G 0.3 H

H 1.2 End

(i) Draw the precedence diagram


(ii) Assign tasks in order of greatest number of following tasks
(iii) Determine the percentage of idle time
(iv) Compute the rate of output that could be expected for this line assuming a 420-minute
working day.

2. As part of a major plant renovation project, the IE department has been asked to balance
a revised assembly operation to achieve an output of 240 units per 8-hour day. Task times
and precedence relationships are as follows:

Task Duration Precedes


(Minutes) Task
A 0.2 B
B 0.4 C
C 0.2 F
D 0.4 E
E 1.2 G
F 1.2 G
G 1.0 End

Do each of the following:

(i) Draw the precedence diagram.


(ii) Determine the minimum cycle time, maximum cycle time and the calculated time
(iii) Determine the minimum number of workstations needed.
(iv) Assign tasks to workstations on the basis of greatest number of following tasks. Use
longest processing time as a tie breaker. If ties still exist, assume indifference in
choice.
(v) Compute the percentage of idle time for the assignment in part (iv).

3. The manufacturing Engineers at Suny Manufacturing were working on a new remote


controlled toy Monster Truck. They hired a production consultant to help them determine
the best ype of production process to meet the forecasted demand for this new product.
The consultant recommended that they use an assembly line. He told the manufacturing
Engineers that the line must be able to produce 600 Monster Trucks per day to meet the
demand forecast. The workers in the plant work 8 hours per day. The task information for
the new Monster Truck is given below:

Task Task time (Secs) Task that must precede


A 28 -
B 13 -
C 35 B
D 11 A
E 20 C
F 6 D, E
G 23 F
H 25 F
I 37 G
J 11 G, H
K 27 I, J
Total 236
i. Draw the schematic diagram.
ii. What is the required cycle time to meet the forecasted demand of 600 trucks per day
based on 8-hour work day?
iii. What is the theoretical minimum number of workstations given the answer in part b?
iv. Assign tasks to workstations on the basis of longest task time with alphabetical order
as the tie breaker and balance the line in the minimum number of stations to produce
600 trucks per day.
v. Assign tasks to workstations on the basis of greatest number of following tasks and
use longest processing time as a tie breaker. Balance the line in the minimum number
of stations to produce 600 trucks per day.

4. A computer manufacturer needs to design an assembly stations in the factory where the
cabinet housing the hard disk, mother board and other accessories is to be made. The
factory currently works for one shift of 8 hours. The tasks, their durations and the
precedence relationships are shown in the following table.

Table 1: The tasks, their duration & precedence relationship

Task Predecessor element(s) Duration (Secs)


A - 70
B A 80
C A 40
D A 20
E A 40
F B, C 30
G C 50
H D,E,F,G, 50

i. If the cycle time is 80 secs, what will the daily production of cabinets be?

ii. If the desired production rate is 320 cabinets per day, what is the maximum permissible cycle
time?

iii. What is the maximum and minimum number of workstations required to maintain this daily
production rate?

iv. Design an assembly set-up with 5 workstations and 6 workstations. What are the key
inferences of this exercise?

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