Golf Carts Inc. must set up an assembly line for golf carts. Forecasts show that

Question

Golf Carts Inc. must set up an assembly line for golf carts. Forecasts show that 9 units per day should be produced. The plant operates one eight-hour shift each day and runs the line continuously during the shifts. The tasks required, task times, and precedence relationships are as follows:

b. What is the takt time? (Round your answer to the nearest whole number.)

c. What is the theoretical number of workstations? (Round up your answer to the next whole number.)

d. Assign the tasks to the workstations to balance the line using the longest operating time rule.

e. What is the efficiency of the balanced line? (Round your answer to 1 decimal place.)

f. If demand increased to 10 units per day, what would be the new takt time? (Round your answer to the nearest whole number.)

Task Time (Minutes) Predecessors A 12 – B 6 – C 22 – D 32 A,B E 15 C F 34 D G 15 E,F

Explanation / Answer

b. Available production time = 8 hrs = 8 * 60 = 480 mins

Customer demand = 9 units/day

TAKT time = 480/9 = 53.34 mins/unit (cycle time) = 53 mins/ unit

c. Minimum number of workstations= sum of total task times / cycle time

                        = (12+6+22+32+15+34+15)/53.34= 2.54 = 3 workstations

d. Assigning tasks to workstation using longest operating time rule:

Longest operating time order and predecessor rule: A-B-D-F-C-E-G

The total station time is nothing but the cycle time. So, total station time of each station is 53 mins.

               Workstation 1:

                        First task =A

                        Time left= 53-12 = 41 mins

                        Second task=B

                        Time left=41-6 = 35 mins

                        Third task =D

                        Time left= 35-32 = 3 mins

                       

So, workstation 1: A-B-D

Workstation 2:

                        First task =F

                        Time left= 53-34 = 19 mins

                       

So, workstation 2: F

Workstation 3:

                        First task =C

                        Time left= 53-22 = 31 mins

                        Second task=E

                        Time left=31-15 = 16 mins

                        Third task =G

                        Time left= 16-15 = 1 min

So, workstation 3: C->E->G

Work Station

Tasks

Workstation Time (mins)

Idle Time (mins)

1

A->B->D

50

5

2

F

34

19

3

C->E->G

52

1

e. Efficiency with 3 workstations = (sum of all tasks) / (no of workstations *   Cycle time)

        = (136)/ (3*53) = 0.855 or 85.5 %

f. If New Demand = 10 units / day

Available production time = 8 hrs = 8 * 60 = 480 mins

TAKT time = 480/10 = 48 mins/unit

Work Station

Tasks

Workstation Time (mins)

Idle Time (mins)

1

A->B->D

50

5

2

F

34

19

3

C->E->G

52

1

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