1. A small electrical appliance is to be produced on a single model assembly lin
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Question
1. A small electrical appliance is to be produced on a single model assembly line. The work content of assembling the product has been reduced to the work elements listed in Table below. The table also lists the standard times that have been established for each element as well as the precedence order in which they must be performed. The line is to be balanced for an annual demand of 100,000 unit/yr. The line will operate 50 wk/yr, 5 shifts/wk, and 7.5 hr/shift. Manning level will be one worker per station. Previous experience suggests that the uptime efficiency for the line will be 96%, and repositioning time lost per cycle will be 0.08 min. Determine: (a) total work content time Twe (b) required hourly production rate RP to achieve the annual demand, (c) cycle time Tc (d) Theoretical minimum number of workers required on the line, and (e) service time Ts, to which the line must be balanced No. Work Element Description Tes(min) Must Be Preceded By 0.2 0.4 0.7 0.1 0.3 0.11 0.32 0.6 0.27 0.38 0.5 0.12 I Place frame in work holder and clamp Assemble plug, grommet to power cord 3 Assemble brackets to frame 4 Wire power cord to motor 5 Wire power cord to switch 6 Assemble mechanism plate to bracket 1.2 7 Assemble blade to bracket 8 Assemble motor to brackets 9 Align blade and attach to motor 10 Assemble switch to motor bracket II Attach cover, inspect, and test 12 Place in tote pan for packing 3,4 6,7,8 5,8 9,10Explanation / Answer
(a) The total work content time = The sum of the work element time = 0.2+0.4+0.7+0.1+0.3+0.11+0.32+0.6+0.27+0.38+0.5+0.12 = 4.0 min
(b) Required hourly production rate RP to achieve the annual demand = Demand/Operational Time = (100,000) / (50×5×7.5) = 53.33 units/hr
(c) The cycle time TC with uptime efficiency of 96% is = (60*E)/RP = (60*0.96)/ 53.33 = 1.08 min
(d) The theoretical minimum number of workers required on a line
W = total work content time / cycle time TC = 4/1.08 = 4 workers
(e) The service time TS to which the line must be balanced = TC- Time lost per cycle = 1.08-0.08 =1.00 min
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