Review Problems and Solutions for

Chapter 6: Process Selection and Facility Layout

For the following three problems (1, 2, 7), we assume that parallel workstations are
not allowed.

1. An assembly line with 17 tasks is to be balanced. The longest task is 2.4 minutes, and
the total time for all tasks is 18 minutes. The line will operate for 450 minutes per day.
a. What are the minimum and maximum cycle times?
b. What range of output is theoretically possible for the line?
c. What is the minimum number of workstations needed if the maximum output
rate is to be sought?
d. What cycle time will provide an output rate of 125 units per day?
e. What output potential will result if the cycle time is (1) 9 minutes? (2) 15
minutes?

Solution:
OT = 450 minutes
a. Minimum cycle time = length of longest task, which is 2.4 minutes.
Maximum cycle time = Σ task times = 18 minutes.
b. Range of output:
450
@ 2.4 min . : = 187.5 units
2.4
450
@18 min . : = 25 units
18
Dx ∑ t 187.5(18)
c. N= = = 7.5, which rounds to 8
OT 450
OT 450
d. Output = Solving for CT, CT = = 3.6 minutes per cycle
CT 125
e. Potential output:
OT 450
(1) CT = 9 min . : = = 50 units
CT 9
450
(2) CT = 15 min . : = 30 units
15

2. A manager wants to assign tasks to workstations as efficiently as possible, and

achieve an hourly output of 33⅓ units. Assume the shop works a 60-minute hour.
Assign the tasks shown in the accompanying precedence diagram (times are in
minutes) to workstations using the following rules:
a. In order of most following tasks. Tiebreaker: greatest positional weight.
b. In order of greatest positional weight.
c. What is the efficiency?
Solution:

Desired output = 33.33 units per hour

Operating time = 60 minutes per hour
Operating time 60 minutes per hour
CT = = = 1.80 minutes per unit
Desired output 33.33 units per hour
a.
Task Number of following tasks Positional Weight
A 7 6
B 6 4.6
C 2 1.6
D 2 2.2
E 2 2.3
F 1 1.0
G 1 1.5
H 0 0.5

Assembly Line Balancing Table (CT = 1.8)

Feasible tasks
Work Station Task Task Time Time Remaining
Remaining
I A 1.4 0.4 –
II B 0.5 1.3 C, D, E
E 0.8 0.5 –
III D 0.7 1.1 C
C 0.6 0.5 F
F 0.5 0 –
 IV G 1.0 0.8 H
H 0.5 0.3 –
b.
Assembly Line Balancing Table (CT = 1.8)
Feasible tasks
Work Station Task Task Time Time Remaining
Remaining
I A 1.4 0.4 –
II B 0.5 1.3 C, D, E
E 0.8 0.5 –
III D 0.7 1.1 C
C 0.6 0.5 F
F 0.5 0 –
IV G 1.0 0.8 H
H 0.5 0.3 –

Total time 6.0

c. Efficiency = = = 83.3%
CT x no. of stations 7.2

7. For the set of tasks given below, do the following:

a. Develop the precedence diagram.

b. Determine the minimum and maximum cycle times in seconds for a desired
output of 500 units in a 7-hour day. Why might a manager use a cycle time of
50 seconds?
c. Determine the minimum number of workstations for output of 500 units per
day.
d. Balance the line using the largest positional weight heuristic. Break ties with
the most following tasks heuristic. Use a cycle time of 50 seconds.
e. Calculate the percentage idle time for the line.
Solution:

a. g

a b c
h i j

d e f

OT 7(60)
b. CT = = = .84 minutes = 50.4 seconds (maximum cycle time)
D 500

Minimum cycle time = maximum task time = 45 seconds (results in 560 units of
production)
∑ t 193
c. N= = = 3.83 or 4 stations
CT 50.4
d.
Task Number of followers *PW
A 6 106
B 5 61
C 4 50
D 4 106
E 3 56
F 2 30
G 2 31
H 2 29
I 1 19
J 0 10
*Positional weight
CT = 50 seconds
Feasible tasks
Work Station Task Task Time Time Remaining
Remaining
I A 45 5 –

III D 50 – –

III B 11 39 C, E
 E 26 13 C, F

C 9 4 –

IV G 12 38 H, F
F 11 27 H
H 10 17 I
I 9 8 –

V J 10 40 –

193
e. I = 1− = 22.8%
(50)(5)

Optional Problem (Parallel workstations are allowed).

Consider the following precedence diagram:

Suppose that OT (operating time per day) = 480 minutes, and our target output rate D is
960 for each day. Balance the line.

Solution:

CT = OT/D = 0.5 minutes. Suppose that we use the number of followers to break ties,
then

Feasible tasks
Work Station Task Task Time Time Remaining
Remaining
I a 0.1 0.4 –
II 0.7 min (task time for c) >0.5 min, new workstations are needed
II & III c 0.7 0.3 -
 IV 1.0 min (task time for b) >0.5 min, new workstations are needed
IV & V b 1.0 0 -
VI d 0.5 0 -
VII e 0.2 0.3 -

Notice that we can use smaller number of workstations. In fact, we can use two
workstations (instead of three) on tasks a and c, i.e., each of these two work station works
on tasks a and c. In other words, we can treat tasks a and c as one task, with a task cycle
time = 0.8 min < (0.5 min x 2 = 1.0 min). Then it is clear that two workstations are
enough for the task (a and c together).