BDA 4012 INDUSTRIAL ENGINEERING

Introduction to Industrial Engineering

3. Use the longest work element rule to balance the assembly line described in the following
table so that it will produce 40 units per hour. Break ties using the largest number of
followers rule.

a. What is the cycle time?

b. What is the theoretical minimum number of work stations?
c. Draw the precedence diagram.
d. Which work elements are assigned to each work stations for line balancing
purposes?
e. What are the resulting efficiency and balance delay percentages?

Work Element Time (sec) Immediate Predecessors

A 40 None
B 80 A
C 30 A
D 25 B
E 20 C
F 15 B
G 60 B
H 45 D
I 10 E,G
J 75 F
K 15 H,I,J
Total = 415

4. Johnson Cogs wants to set up a line to serve 60 customers per hour. The work elements and
their precedence relationships are shown in the following table.

a. What is the theoretical minimum number of stations?

b. How many stations are required if the longest work element time method is
used?
c. How many stations are required if the largest number of followers method is
used?
d. Suppose that a solution requiring five stations is obtained. What is its
efficiency?

Work Element Time (sec) Immediate Predecessors

A 40 None
B 30 A
C 50 A
D 40 B
E 6 B
F 25 C
G 15 C
H 20 D,E

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BDA 4012 INDUSTRIAL ENGINEERING
Introduction to Industrial Engineering
I 18 F,G
J 30 H,I
Total = 274

5. The Baxter Bicycle Company is installing a line to produce a new line of BMX bicycles,
and you, as the operations manager, are responsible for designing the line. The line has to
produce 576 units per day, and the company operates three 8-hour shifts each day. The
work elements, time requirements, and immediate predecessors are as follows:

Work Element Time (sec) Immediate Predecessors

A 75 None
B 50 A
C 30 B
D 25 B
E 45 B
F 55 D
G 70 D
H 50 F,G
I 25 E
J 90 C,H,I

a. What is the theoretical number of stations?

b. If you balance the line using the longest work-element time rule, which elements
are assigned to station 3?

6. An assembly line must produce 40 microwave ovens per hour. The following data give the
necessary information:

Work Element Time (sec) Immediate Predecessors

A 20 None
B 55 A
C 25 B
D 40 B
E 5 B
F 35 A
G 14 D,E
H 40 C,F,G

a. Draw a precedence diagram.

b. What cycle time (in seconds) ensures the desired output rate?
c. What is the theoretical minimum number of stations and the theoretical maximum
efficiency?
d. Use the longest work-element rule to design the line. What is its efficiency?
e. Can you find any way to improve the line’s balance? If so, explain how?

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BDA 4012 INDUSTRIAL ENGINEERING
Introduction to Industrial Engineering