Professional Documents
Culture Documents
Process/Assembly Line
Rohit Kapoor
Job Shop
JOB SHOP
Key Issues in Managing Job Shops
Capacity management
- shifting bottlenecks
- setups/changeover times
- rework
- work-in-process (WIP) movement
- cross functional training
- functional coordination
JOB SHOP
Key Issues in Managing Job Shops
Batch Process
Batch Process
Key Issues in Managing Batch Process
Planning & Forecasting
Determining batch sizes
Capacity management
Capacity is limited here.
Batch Process
Key Issues in Managing Batch Process
Planning & Forecasting
Determining batch sizes
Capacity management
Capacity is limited here.
Assembly Line
Illustration 1
A production line operating 450 minutes per
day is to have an output of 250 units per
day. Find the cycle time.
Illustration 2
The precedence diagram for assembly activities A through H is shown
below, with the element time requirements shown in minutes. The line
operates 7 hours per day, and an output of 600 units per day is desired.
Compute cycle time and (b) the theoretical minimum number of
stations.
Illustration 3
Using the data and precedence diagram from Illustration 2
(a) group the assembly-line tasks into an appropriate number
of workstations using the longest work-time rule, and (b)
compute the balance efficiency and (c) the idle time.
Illustration 4
Suppose the activities shown in Fig. are to be grouped into a threestation assembly line.
(I)What is the target cycle time?
(II) Which grouping of activities results in the largest output per
hour?
(III) What output will result in a 7 -hour day?
Illustration 5
Tasks A through I have the predecessor and time requirements
shown in Table. Output is to be 200 units per day, and operating
time is 450 minutes per day. Using the most successors rule to
assign tasks to work centers, and the longest work-time rule as a
tie breaker, (0) group the tasks into work centers, WCs, and
compute (b) the balance efficiency, (c) the idle time, and (d) the
balance delay.
Task
A
B
C
D
E
F
G
H
I
Predecessor
None
A
None
C
D
None
F
G
H
Time (see)
40
20
60
40
30
35
45
60
40
Fig. B
Time
Preceding
(sec)
Task(s)
10
None
24
None
17
49
12
14
27
20
F, G
23
D, H, I
36
18
J, K
(a) Draw a precedence diagram. (b) What is the theoretical minimum (target)
cycle time if all five robots are fully utilized in a five-station assembly line?
(c) Group the tasks into the most efficient five-station assembly line. (d)
What is the cycle time? (e) What is the balance efficiency?
Assembly Line
Key Issues in Managing Assembly Lines
Time standards
Assembly line balancing
Rebalancing
Material availability/Materials and Supplier relations.
Worker incentives
Capacity Planning
Plant Loading/Production planning
Product design
Product Mix
Sequencing (to maintain balance)