Problem Answers

Chapter 10

1. Required cycle time = 1 minute / unit

Whether the cell should be developed for that cycle time depends upon the
accuracy of the forecast.

2. (a) Required CT for part A = 90 sec /unit

(b) Required CT for part B = 64 sec / unit

The required minimum production capacity of the process is 450 units per
day.

3. Worker 1 CT = 323 sec / unit and worker 2 CT = 392 sec / unit, thus the
cycle time for the process is 392 sec / unit.

(a) Required daily capacity = 70.24 or 71 units

(b) Since the CT of the process is < Required CT (410 sec), the
workcell has adequate capacity.

4. (a) Time to produce 71 units

For worker 1, 392 sec / unit (71 units) = 27, 832 sec
For worker 2, 323 sec / unit (71 units) = 22, 933 sec

Assuming an 8-hour day for both workers, available labor time =

57,600 sec. This results in 6835 sec of idle time or about 11.9%.

(b) 73.46 units

5. (a) Cycle time would be the same as the slowest worker, 15 min.
With 3 workers cycling around the cell the average cycle time
would be 5 min / unit.

(b) In 15 minutes one worker gets one unit

In 15 minutes one worker gets 15 / 14 =1.07 units

1
 In 15 minutes one worker gets 15 / 13 = 1.15 units
Therefore, in 15 minutes three workers would get 3.22 units and
the CT = 15 minutes / 3.22 units = 4.66 minutes / unit.

6. (a) Since the manual time at station 5 is now only 10 sec, the cell CT is
reduced by 30 sec to 421 sec / unit.

(b) The manual times at stations 7 and 8 are each reduced by 70

seconds, so the cell CT is reduced by 140 seconds to 451 – 140 =
311 sec / unit

(c) Discussion question. To be addressed in class.

See last page for additional information before beginning work on

problem #7.

7. (a) Worker 1 has incoming outgoing material and operations 1 and 8.

Worker 2 has operations 2 and 7
Worker 3 has operations 3 and 6
Worker 4 has operations 4 and 5

CT (worker 4) = 90 + 18 = 108 sec / unit

CT (worker 3) = 60 + 27 = 87 sec / unit
CT (worker 2) = 130 + 27.5 = 157.5 sec / unit
CT (worker 1) = 120 + 25.5 = 145.5 sec / unit

Therefore, CT = 157.5 sec / unit

Daily Capacity = (480 min / day x 60 sec / min) / 157.5 sec / unit
= 182.9 units

(b) worker 1 has incoming and station 1

worker 2 has station 2
worker 3 has station 3 and 4
worker 4 has station 5 and 6
worker 5 has station 7
worker 6 has station 8 and outgoing

worker 1 CT = 40 + 8 = 48 sec / unit

2
 worker 2 CT = 50 + 9 = 59 sec / unit
worker 3 CT = 21 + 70 = 91 sec / unit
worker 4 CT = 17 + 80 = 97 sec / unit
worker 5 CT = 9 + 80 = 98 sec / unit
worker 6 CT = 9.5 + 80 = 89.5 sec / unit
Therefore CT = 97 sec / unit

Daily Capacity = (480 min / day x 60 sec / min) / ( 97 sec / unit) =

= 296 units

(c) Four workers

Labor cost = $80 / hr ; CT = 157.5

Cell Output Rate = 22.86 units / hr
Unit cost = $7.00 per unit

Six workers

Labor cost = $120 / hr

Cell Output Rate = 37.11 units / hr
Unit cost = $ 5.39 / unit

Comparing these costs with the costs given in the chapter , the lowest
cost case is for four workers.

8. Refer to problem 7a for worker assignments.

Worker Setup Walk CT (sec) Longest Subcell CT

mach. (sec)
Run+SU
1 2(10) 25.5 45.5 80 80
2 2(10) 27.5 47.5 80 80
3 2(10) 27 47 40 47
4 2(10) 18 38 50 50

Therefore, cell CT = 80 sec / unit

Daily Capacity = (480 min /day x 60 sec / min) / (80 sec / unit) = 360 units

3
 (c) Dividing the workcell among five workers to reduce the cell CT to at
least 40 sec / unit requires additional machines at stations 2, 4, 7,
and 8

Worker Setup Walk CT Longest Subcell CT

run + SU (sec)
1 2(10) 16.5 36.5 50/2 = 25* 36.5
2 2(10) 16.5 36.5 50/2 = 25* 36.5
3 2(10) 12 32 40 40
4 10 16 26 80/3= 26.7
26.7*
5 10 16 26 80/3 = 26.7
26.7*
*Denoted multiple machines visited on an alternating basis.

Therefore, cell CT = 36.5 sec / unit

Daily Capacity = (480 min /day x 60 sec / min) / (36.5 sec / unit) = 789 units

9. Assume the walk times between stations are as shown in Figure 10.7.
The operation times shown are for one unit. Assume items are processed
in batches of 6 units at a time, and allow 3 seconds handling for each unit
at each station.

Time for worker to complete one cycle around the cell

= (operation time at 8 stations ) + walk times
= [400 sec + 8 (3 sec)] (6 units) + 51 sec = 2595 sec

CT = [2595 sec / batch] / [6 units / batch] = 432.5 sec / unit

10. Worker CT = setup times + walk time = 134 + 60 = 194 sec

CT (A) = 175
CT (B) = 204
CT © = 227
CT (D) = 218

Therefore, machine C controls the overall cycle time with 227 seconds.

4
11. Add 2 seconds to machine operating time to allow for loading- unloading
between parts:

Divide the setup time of each machine by 20 to determine how much the
overall cycle time will be increased.

Machine A B C D
Operation Time 154 175 177 192
(sec/unit)
23/20 = 1.15 31/20 = 1.55 52/30 = 2.60 28/20 = 1.4
Total CT 155.15 176.55 179.60 193.4
The walk time and the

For single unit production (problem 10a)

Daily Capacity = [480 min/day x 60 sec/min] / [227 sec unit] = 126.9 units

For 20-unit batch production:

Daily Capacity = [480 min /day x 60 sec / min] / [193.4 sec / unit] = 148.9
units

Notice that batching does not greatly reduce the cell CT because the manual
(setup and walk) times and the longest machine unit-operating times are close
in value. When the unit operating times are much smaller than the manual
times, however, then batching significantly reduces cell CT.

5
Times used in moving in problem #7