Task 3.

Assembly line balancing

a) Draw the schematic diagram. Which process step defines the maximum rate of production?

1 4 7 10

0,6 0,8 1,1 0,7

13 15

1,1 1,0
2 5 8 11 16 17

1,4 1,3 1,2 1,3 0,7 0,7

3 6 9 12 14

0,7 1,1 0,9 0,9 2,0

Task 14 is the minimum takt time time of the line and therefore, the maximum rate of
production.

b) Define the maximum number of vacuum cleaners which can be produced within 8 working
hours at this assembly line.
8 / 2 = 4 vacuum cleaners

c) Define cycle time for production of 16 vacuum cleaners a week (40 hours).
40 / 16 = 2,5 hours = takt time

d) Define theoretical minimal number of workstations for production of 16 vacuum cleaners!

17,5 / 2, 5 = 7 stations

ti
M min i
C

e) Is it possible to produce 20 vacuum cleaners a week? If so how many workstations do you

need for production of 20 vacuum cleaners?

40 / 2 = 20 units yes it is possible

17,5 / 2 = 8,75 9 stations
f) Balance the line in the minimum number of stations to produce 16 vacuum cleaners a week!

Station Task Station time Idle time Takt time=2,5 h

1 1,2 2.0 0.5
2 4,5 2.1 0.4
3 3,8 1.9 0.6
4 7,6 2.2 0.3
5 9,11 2.2 0.3
6 10,13 1.8 0.7
7 12,15 1.9 0.6
8 14 2.0 0.5
9 16,17 1.4 1.1
5.0

Task Number of followers

17 0
16 1
15 2
14 2
13 3
12 3
11 4
10 4
9 4
8 5
7 5
6 5
5 6
4 6
3 6
2 7
1 7

g) Define the idle time from (f) and suggest some ways for using those times.

Idle time = 5.0 hours a cycle

Ways of use: maintainance, setups, switch off,

h) Define the efficiency of your assembly line from (f)

E = 17,5 / (9*2,5) = 77,8%