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Assignment Chapter 4
1 Total time for all workelements at the certain assembly line is 7,8 minustes.
The average stopped time (break down time) is 5%, the required
production rate is 80 items per hour.
a) Determine the minimum theory number of workstations to optimize total
wastes time. [11 Ws]
b) Determine percentage of balance loss L%. [5,45%]

2 A certain electronic appliance that have total processing time for all
workelements is 9,2 minutes. The acctual required volume is 80
items/hour (actual productivity). The current operational information as
follow: an 8-hour shift per day, however, the actual operating time 6
hours, and the rest time for stopping and waste.
a) Determine the minimum theory number of workstations to optimize total
wastes time.
b) Determine percentage of balance loss L%.

3 The certain items are manually produced with 10 workers in line, the hourly
cost is 7,000 VNĐ per person, the operating time is 8 hours per shift, 6
shifts per week, and 51 weeks per year. The total processing time to
complete this item is 3.1 minutes. A production line designed request is
released to meet a certain demand 85 units per hour (round up to 2
decimal).

a) Determine the cycle time TC for this item?

b) Determine the minimum theory number of workstations to optimize total
wastes time.
c) Suppose that the new line is designed and balanced with 5 stations.
This new line is optimal solution or not? Why?. Do you think you can
improve this new line by reducing number of stations?
d) Determine percentage of balance loss L% (with 5 stations in question
c).
e) Suppose that the new line is designed and balanced with 6 stations,
and each station is run by one worker. Determine the yearly benefit of
the designed line.
4 (Case study and discussion) A certain kind of items is produced in
production line including 5 stations. The weekly demand of this item is 4,000
units, and total operating time is 48 hours per week.
77 Chương 4

a. Determine the available time for each item to produce in this line (available
processing time for each item)?
b. The factory manager said that the actual cycle time of this item is TC = 0,70
minutes, and the percentage of balance loss L = 10%, respectively.
Determine the total processing time for all work-elements?
c. In this week, the factory manager reported that the actual volume is only
meet actual demand. Determine total stopped time if the cycle time is TC =
0,70 minutes?
d. The factory is employed over/under time policy. If the order from
marketing and sales is 5,800 units for next week, the stopped time
percentage is 1% of total operating time (both regular and over time). TC =
0,70 minutes. Determine the neccessary over time for next week to meet
this demand?
e. Acording to forecasting demand, the weekly demand for this item is
increased to 5,800 units/week. A new designed line including 4 stations is
considered to meet this demand. The yearly investment for the new line is
80,000,000 VNĐ. The total volume of this line is 5,800 units/week without
over time. The hourly cost is 10,000 VNĐ for each worker in regular time,
and 16,000 VNĐ in over time, each station is run by one person, and
working weeks are 50 per year. The savage value of current line is zero. Do
you think this new line is feasible or not, why?

5 (Case study and discussion) A certain electronic toy has total processing
time for all work-elements is 8,2 minutes, and the weekly demand for this item
is 2000 units. The weekly operating time is 40 hours.

a) Suppose that the current line at this factory includes 6 stations, this
current line meets weekly demand or not? If not, propose a feasible
solutions without new machines investment?
b) Suppose new line investment, determine the theoretical minimum
number of stations to optimize total waste time?
c) Determine percentage of balance loss L%.
d) According to factory report, the cycle time increased 10% in last week,
because of broken machines. Determine the actual volume and total
stopped time in last week?

4.15 A certain electronic item is produced at manual line that includes 6

employees, the hourly wage for each employee is 6.000 VNĐ, the
operating time is 8-hour per shift, and 6-shift per week, and 50-week per
year. To meet customers’ demand, a new production line should be
designed. Suppose that a new line is designed which includes 4 stations
and detailed allocated jobs in below table:
Hệ thống sản xuất khối lớn
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Processing Cummulative Remained

Station Jobs
time time time
(minutes) (minutes) (minutes)
0 0.42 0.42 0.78
I 1 0.30 0.72 0.48
3 0.18 0.90 0.30
2 0.40 0.40 0.80
II 5 0.36 0.76 0.44
4 0.36 1.12 0.08
6 0.60 0.60 0.60
II
8 0.42 1.02 0.18
7 0.25 0.25 0.95
IV 9 0.10 0.35 0.85
10 0.51 0.86 0.34

a) Determine the hourly production rate (in design) of this line?

b) Determine the actual hourly production rate of this line?

c) Determine the minimum theory number of workstations based on demand

and production data?

d) The above 4-machine designed line is optimum or not? Why?

e) Determine total balance loss L% of the designed line?

f) Suppose that each person runs one station in this line. Determine the
yearly benefit of this line?