IN AN INTRO, LOOK FOR 2 VALUES

1. OUTPUT RATE, OR
2. PRODUCTIVE TIME, PT
(CAN ALSO BE STATED IN THE QUESTION WHICH RELATES TO
CYCLE TIME, CT)

1. CLEARLY STATED AS PT OR
2. STATED AS “AVAILABLE TIME”/ “ALLOCATED TIME”
3. STATED AS “WORKING HOURS”
4. WORKING HOURS GIVEN, BUT PERCENTAGE OF PRODUCTIVE TIME IS
STATED

3. DIFFERENT QUESTION FORMAT:

 PRODUCTIVE TIME, PT Question 1
1. CLEARLY STATED AS PT
PT = 60 mins * 7 hours * 60 secs = 25, 200 secs/day
hour day min

OR = 315 units/day
INTRO

TASK

TABLE

500

idleness percentage

if wage rate is given in a daily basis, you HAVE to change it to per hour basis
RM25
day =RM 3.57/hour
7 hours
day
 Task
a) Precedence Diagram (in seconds)

Precedence / Sequence

45 65 20
A C F

15

D
35
75
B H
55 50
80 60
I J
E G

Σ Task Time = 500 seconds

Cycle Time, CT = PT / OR
OR = 315 units/day
PT = 25, 200 secs/day

CT = 25, 200 secs

day = 80 sec/unit
315 units
day ≤ 6.44 —> 6
> 6.45 —> 7

b) Theoretical # of WS = Σ Task Time = 500 secs = 6.25

80 sec/unit ~ 6 units of ws
CT
 c)

WS 1 2 3 4 5 6 7

TASK(S) A, B C, D E F, G H I J
TASK TIME (TT) 80 80 80 80 75 55 50
IDLE TIME (IT) 0 30
0 0 0 5 25
= CT - TT
= 60 SECS

d) efficiency of the line = Σ Task Time * 100%

(no of ws from the line layout * CT)
= 500 secs * 100% = 89.29%
7 units * 80 secs
unit
Balance of Delay % = 100% - Efficiency = 100% - 89.29% = 10.71%
OR

when question asked for

= 60 secs * 100% = 10.71%
MONTHLY / WEEKLY/ DAILY
cost of idleness, THEN you need to make sure
OR is ALSO in MONTHLY/WEEKLY?DAILY
7 units * 80 secs
unit
e) Cost of Idleness per month
1) idle time per unit = 60 secs/unit

2) OR in a month = 315 units * 5 days * 4 weeks = 6300 units/month

day week month
3) idle time in a month = 60 secs * 6300 units = 378,000 sec/month
unit month
4) idle time in hours/month = 378,000 secs = 105 hours/month
month
3600 secs
hour
5) Cost of Idleness per month = 105 hours * RM 3.57 = RM374.85 / month
month hour
 Question 2
PRODUCTIVE TIME, PT
2. STATED AS “AVAILABLE TIME”/ “ALLOCATED TIME”
CONFIDENTIAL BA/DEC 2019/MGT345/375

PART A

QUESTION 1

Adidos Manufacturing Sdn Bhd produces high quality shoes. Manufacturing these shoes
require 10 separate tasks. There are 420 minutes available for manufacturing the shoes in
the plant each day and the weekly demand is 300 shoes. The information for the tasks is as
follows:

TASK TIME
TASK (MINUTES) PREDECESSOR
A 1 -

B 3 A
C 2 B
D 4 B
E 1 C,D
F 3 A
G 2 F
PT = 420 mins/day * H 5 G
5 days/week I 1 E,H
= 2100 mins/week J 3 I
OR = 300 units/week
a) Draw the precedence diagram of the operation.
(4 marks)

b) Assuming a 5 days work a week, calculate the cycle time of the line.
CT = PT/OR = 2100 mins/week (1.5 marks)
300 units/week
= 7 mins/unit
c) Determine the theoretical minimum number of workstations.

# of WS = 725 mins
mins/unit
= 3.57 ~ 4 unit of WS (1.5 marks)

d) Construct the line layout of the operation.

(2 marks)

e) Compute the resulting efficiency and balance of delay percentages.

(2 marks)
a) Precedence Diagram (in mins) 3 2
F G
5
2
H
C 1 1 3
1 3
A B 4 E I J
D Σ Task Time = 25 mins

© Hak Cipta Universiti Teknologi MARA CONFIDENTIAL

 C) Precedence Diagram (in mins)

WS 1 2 3 4

TASK(S) A, B, F C, D, E G, H I, J

TASK
7 7 7 4
TIME

IDLE 0 0 0 3 IDLE TIME = 3 MINS/UNIT

TIME

d) EFFICIENCY = 25 MINS * 100 = _______________________

(4 UNITS * 7 MINS/UNIT)

e) cost of idleness per month

= 3 mins/unit * ( 300 units/week *4 weeks/month) * RM6.25/hour

60 mins/hour

= RM 375 /MONTH
PRODUCTIVE TIME, PT Question 3
2. STATED AS “AVAILABLE TIME”/ “ALLOCATED TIME”

OR
 Question 4
PRODUCTIVE TIME, PT
3. STATED AS “WORKING HOURS”

OR

CT
PRODUCTIVE TIME, PT Question 5
4. WORKING HOURS GIVEN, BUT PERCENTAGE/AMOUNT OF
CONFIDENTIAL 2 BM/MAY 2012/MGT345/365/375
NON- PRODUCTIVE TIME IS STATED.
NEED TO CALCULATE PT = Working Hours - Non Productive time
PART A
OR
QUESTION 1

VC Enterprise, an original equipment manufacturer (OEM) of laser printer is in the process of

setting up a new production line for its laser printer assembly. Its policy is to operate in 2
working shifts daily in which 3.10 hours are considered non productive. The number of
printers produced is estimated to be 3870 units weekly, assuming that the employees work
8-hours per shift and 5-day workweek. The following table shows all the tasks required to
produce a unit of laser printer.

Task Predecessor (s) TIME (Seconds)

A - 33
B A 27
C A 34
D B, C 29
E C 29
F D 25
G - 26
H F, I 16
I E, G 33
J I 22
K H, J 18

a) Construct the precedence diagram for this production line

(3 marks)

b) Compute the cycle time for a laser printer.

(2 marks)

c) What is the theoretical number of workstations required?

(1 mark)

d) By using the Longest Task Time Heuristic approach, balance the production line and
draft the layout with a suitable diagram.
(3 marks)

e) Calculate the efficiency of the production line.

(1 mark)

f) If wages per worker cost RM5 per hour, what is the cost of idleness per week?

(2 marks)

© Hak Cipta Universiti Teknologi MARA CONFIDENTIAL

 OR
PT , stated in b) question, thus need
to calculate OR
FIRST, NEEDS TO FIND CT VIA THE TABLE!, LOOK FOR THE HIGHEST
TASK TIME, THIS TASK TIME IS THE CT

THIS IS THE CT

Σ Task Time
= 57 mins

CT = PT OR = PT = 480 MIN
OR
Doesn’t ask us to find CT CT DAY
12 MINS
PT = 8 hours * 60 mins = 480 mins UNIT
day hour day = 40 UNITS
DAY

e) Efficiency = 57 mins = 95%

* 100%
5 units * 12 mins
unit

Balance Delay % = 100% - 95% = 5%

 2 RULES:
a) Precedence Diagram 1. ASSIGN TASK(S) WHOSE TOTAL TASK TIME IS LESS OR
EQUAL TO CT
2. ASSIGN TASK(S) ACCORDING TO ITS/THEIR
3 PRECEDENCE/SEQUENCE

WS 1 D WS 1
A, B, D 12 MINS
WS5 A 5 MINS
5 B 4 MINS
A, B 9 MINS
A
12 WS2 7 3
WS3
C H J

4 5 2 WS 2
B E F C 12
WS4 G 5

5 11
G I Σ Task Time
= 57 mins

c) Theoretical # of WS = 57 mins = 4. 75 ~ 5 units of WS

12 mins
unit

d) Line layout

WS 1 2 3 4 5

TASK(S) A, B, D C E, F, G I H,J
TASK TIME(TT) 12 12 12 11 10
IDLE TIME 0 0 0 1 2
= CT - TT
Σ Idle Time = 3 mins

change to Hourly Wage Rate

f) Daily Wage rate = RM35
= RM4. 38/hour
day
8 hours
day

Cost of Idleness per Day = 3 mins * 40 units * RM4. 38

= RM 8.76
unit day hour
day
60 mins
hour