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Problem 6-22 Francis Johnsons plant needs to design an efficient assembly line to make a new product. The assembly line needs to produce 24 units per hour, and there is room for only five workstations. The tasks and the order in which they must be performed are shown in the following table. Tasks cannot be split, and it would be too expensive to duplicate any task TASK TIME IMMEDIATE TASK (MINUTES) PREDECESSOR 1.0 1.0 2.5 1.5 A, B, C 1.5 2.0 b. What is the workstation cycle time required to produce 24 units per hour? (Round your answer to 1 decimal place Workstation cycle time d. Balance the line to use the fewest possible workstations to meet the cycle time found in part b. Use whatever method you feel is appropriate. minutes What is the efficiency of your line balance, assuming the line operates at the cycle time from part b? (Round your answer to 1 decimal place.) Efficiency

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Available time Desired output Workstation Cycle time = Available Time / Desired output rate 60 24 2.5 minutes units minutes b) minutes Total Task Time Min # of stations needed - Total Task time /Cycle Time rounded up Draw Precedence diagram Assignment of tasks to workstations Work Eligible TaskTask Assigned Task Cumulative Idle TimePredeces Task Time Time 2.5 1.0 2.0 1.5 2.5 2.0 1.5 Time 2.5 1.0 1.0 station minutes 1.0 1.0 2.5 1.5 1.0 1.5 2.0 10.5 sor A,B,C A,B,E B,E D,E 0.5 A,B,C 1.0 2.0 1.5 0.5 1.0 2.0 F,G Total End Total Idle Time 2.5 Cycle time Proposed # of w/s Idle Time per cycle (minutes)2 Lead time (minutes) Efficiency of assembly line minutes 12.5 = Cycle Time x number of stations d) -10.5/12.5 = Total Task Time/ Lead Time 84.0%

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