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What is the best way to group the work represented by the 16 workgroups for an average demand of 306 outgoing wires per day? What is your line balance if peak demand is 450 wires per day? What is assembly-line efficiency for each line balance solution?
C=1.0 min/wire (457 wires/day)
Cycle time: 1.47 minutes/wire (306 wires/day)
Work station Tasks Total Time Idle time
1 1 0.8 .20
2 2 0.3 .70
3 3,4 0.9 .10
4 5 1.0 0.0
5 6,7,8 0.9 .10
6 9 1.0 0.0
7 10,11,12,13 1.0 0.0
8 14,15 0.4 .60
9 16 0.75 .25
Work station Tasks Total Time Idle time
1 1,2 1.1 .37
2 3,4 0.9 .57
3 5,6,7 1.4 .07
4 8 0.5 .97
5 9,10,11,12 1.25 .22
6 13,14,15 1.15 .32
7 16 0.75 .72
Advantage of 9 employees: saves money, less idle time, room to work with employees
Disadvantages of 9 employees: doesn't save as much money
Advantages of 7 employees: saves the most money
disadvantages of 7 employees: a lot of risk, and high cost of failure
Having 9 employees seems most reasonable
How many people are needed for outgoing wires using assembly line balancing methods versus the current staffing level of 11 full-time equivalent employees?
By grouping work using assembly line balancing you
need 7 people not 11 as currently assigned if you plan for average demand of 306 wires per day.
Labor Savings: (4 employees)($30,000)(1.30)=$156,000
Total Time Available = (# work stations)(Cycle Time) = N*CT = 7(1.47)= 10.29 minutes
Total Idle Time = N*CT-Et = 7(1.47) - 7.05 = 3.24 minutes
Assembly Line Efficiency = Et/(N*CT) = 7.05/(7*1.47) = 68.85%
Balance Delay = 1 - Assembly Line Efficiency = 1.0 - .6885 = .3115 or 31.15%
Therefore, by grouping work using assembly line balancing you need 9 people, not 11 as currently assigned
labor savings= 9 (2 employees)($30,000)(1.30)= $78,000
Total Time Available = (N*CT) = 9(1)=9.0 min
Total Idle Time= N*CT-Et= 9(1)-7.05=1.95 min
Assembly Line Efficiency= Et/(N*CT)= 7.05/(9*1)= 78.33%
Balance Delay= 1 - Assembly Line Efficiency= 1.0-.7833= 21.67%