Numerical

Numerical
A final assembly plant for a new automobile model is to
have a capacity of 180,000 units annually. The plant
will operate 50 weeks/yr, two shifts/day, 5 days/week,
and 7.5 hr/shift. It will be divided into three
departments: (1) body shop, (2) paint shop, (3) general
assembly department. The body shop welds the car
bodies using robots, and the paint shop coats the
bodies. Both of these departments are highly
automated. General assembly has no automation.
There are 15.0 hr of work content time on each car in
this third department, where cars are moved by a
continuous conveyor. In addition to the workers
assembling the product on the line in general
assembly, there are 25 utility workers. Determine (a)
hourly production rate of the plant, (b) number of
workers and workstations in general assembly, given

Numerical

Production rate for a certain assembled product

is 48 units/hr. The assembly work content time
= 35 min. The line operates at 92% uptime. Ten
workstations have two workers on opposite
sides of the line so that both sides of the
product can be worked on simultaneously. The
remaining
stations
have
one
worker.
Repositioning time lost by each worker is 0.15
min/cycle. It is known that the number of
workers on the line is two more than the
number required for perfect balance. Determine
(a) number of workers, (b) number of
workstations, (c) balance efficiency, and (d)
average manning level (ignore utility workers).

Numerical
The work content time is 50 min for a product
assembled on a manual production line. The
line uses an overhead conveyor that moves at
1.2 m/min. There are 27 workstations on the
line, one-third of which have two workers; the
rest have one worker each. Repositioning time
per worker is 9 sec, and uptime efficiency is
95%. (a) What would be the hourly production
rate if the line were perfectly balanced? (b) If
the actual production rate is 35 units/hr, what
is the balance efficiency of the line? (c) To
compensate for service time variability, it has
been decided that the tolerance time should be
50% greater than the cycle time. To achieve

Numerical
The production rate of a manual assembly line is 38
units/hr. The work content time of the product
made on the line is 24.8 min. Work units are
attached to a moving conveyor whose speed = 1.5
m/min. Repositioning time per worker is 8 sec, line
efficiency is 96%, and manning level is 1.25
(ignoring utility workers). Owing to imperfect line
balancing, the number of workers needed on the
line is about 10% more than the number required
for perfect balance. If the workstations are
arranged in a line, and the length of each station is
3.5 m, (a) how long is the entire production line,
and (b) what is the elapsed time a base part spends
on the line?