Assembly Lines

Worked out Problems:

Problem1. A product whose work content time = 50 min is to be assembled on a

manual production line. The required production rate is 30unit/hr. From
previous experience with similar products, it is estimated that the manning
level will be 1.25. Assume that the proportion uptime E = 1.0 and that the
repositioning time = 0.Determine: (a) cycle time and (b) ideal
minimum number of workers required on the line.

Problem2. A manual assembly line has 15 workstations with one operator per station.
Work content time to assemble the product =22min. The production rate of
the line =35 units/hr. Assume that the production uptime E = 1.0 and the
repositioning time =6sec. Determine the balance delay.

Problem3.A small electrical appliance is to be produced on a single model assembly line.

The work content of assembling the product has been reduced to the work
elements listed in table 1. The table also lists the standard time that have been
established for each element as well as the precedence order in which they
must be performed. The line is to be balanced for an annual demand of 100,000
units / yr. The line will operate 50 wk /yr, 5shifts /wk, and 7.5 hr /shift.
Manning level will be one worker per station. Previous experience suggests
that the uptime efficiency for the line will be 96%, and repositioning time lost
per cycle will be 0.08 min. Determine: (a) total work content time , (b)
required hourly production rate RP to achieve the annual demand, (c) cycle
time , (d) theoretical minimum number of workers required on the line, and
(e) service time to which the line must be balanced.
Problem4. Solve problem 3 using largest candidate method.

Problem5. Solve the problem 3 using kilbridge and Wester method.

6. A manual assembly line must be designed for a product with annual demand =
100,000 units. The line will operate 5owk/yr, 5shift/wk and 7.5 hr/shift. Work
units will be attached to a continuously moving conveyor. Work content time =
42.0 min. Assume line efficiency E= 0.97, balancing efficiency = 0.96 and
repositioning time = 6 sec. Determine: (a) hourly production rate to meet
demand and (b) number of workers required.
7. A single model assembly line is being planned to produce a consumer
appliances at the rate of 200,000units/yr. The will be operated 8hr/shift, 2
shift/days, 50 wk/yr. Work constant time =35.0 min. For planning purposes, it
is anticipated that the proportion uptime on the line will be 95% Determine (a)
average hourly production rate ,(b) cycle time and (c) theoretical
minimum number of workers required on the line .(D) if balance efficiency is
0.93 and the repositioning time = 6 sec, how many workers will be required?
8. An overhead continuous conveyor is used to carry dishwater base parts along a
manual assembly line .The spacing between appliance=2.2 m, and the speed of
the conveyor=1m/min. The length of each workstation is 3.5 m. there are a
total of 25 stations and 30 workers on the line. Determine (a) elapsed time a
dishwater base part spends on the line (b) feed rate, and (c) tolerance time.

9. The table below defines the precedence relationships and element time for a
new mode toy. (a) Construct the precedence diagram for this job. (b) If the
ideal cycle time = 1.1 min, repositioning time =0.1 min, and uptime proportion
is assumed to be 1.0, what is the theoretical minimum number of workstations
required to minimize the balance delay under the assumption that there will be
 one worker per station? (c) Use the largest candidate rule to assign work
element to stations. (d) Compute the balance delay for your solution.

10. Solve Problem 4 using the Kilbridge and Westor method inpart ©

Suggested Brief Answers:

Ans 1
Given data
Work content time = 50 min, Production rate = 30 units /hr
Manning level H = 1.25, Proportion uptime E = 1.0
Repositioning time =0
(a) Cycle time

= = (60×1)/30 = 2 min
(b) Ideal minimum number of workers required.

W* = Minimum integer ≥ = = 25

Ans 2

Given data
Number of workstations n =15, work content time = 22 min
Production uptime E =1.0, repositioning time =6sec
Production rate = 35 units/hr
The cycle time is given by

= = (60×1)/35 = 1.7 min

 And = - = 1.7 – 0.1 = 1.6 min
Balance delay is given by

d= = (15×1.6 -22)/ (15×1.6) = .083

Ans 3

(a) The total work content time is the sum of the work element time in Table 1
= 4.0 min
(b) Given the annual demand, the hourly production rate is
= 100,000 / (50×5×7.5) = 53.33 units/hr
(c) The corresponding cycle time TC with an uptime efficiency of 96% is
= 60(0.96)/ 53.33 = 1.08 min
(d) The theoretical minimum number of workers

W* = Minimum Integer ≥

= = 4 workers

(e) The available service time against which the line must be balance is
TS = 1.08-0.08 =1.00 min
Ans 4The work elements are arranged in descending order according to their
values given in table.

Work elements are arranged in descending order in table 2, and the algorithm is
carried out as presented in table 3. Five workers and stations are required in the
solution. Balance efficiency is compound as:
 Fig2 Solution for given problems which indicate (a) assignment of elements
according to the largest candidate rule and (b) physical sequence of station
with assigned work elements.

= 4/ (5×1.0) = 0.80
Balance delay d= 0.20. The line balancing problem presented in fig 2.

Ans 5
In the Kilbridge and Wester method, work elements in the precedence diagram are
arranged in to column as shown in fig 3. The element can then be organized in
to a list according their column, with the element in the first column listed first.

We have developed such a list of elements for our problem in table 4. If a given
element can be located in more than one column, then list all of columns for
that element, as we have done in the case of element 5.In our list, we have
added the feature that elements in a given column are presented in the order of
value; that is we have applied the largest candidate rule within each
column. This is helpful when assigning elements to stations, because it ensure
that larger elements are selected first , thus increasing our chance of making
the sum of in each station closer to the allowable limit. Once the list
is established, the same three step procedure is used as before.
 The work elements are arranged in order of column in Table 4. The
Kilbridge and Wester solutions are presented in Table 5. Five workers are
again required, and the balance efficiency is once more = 0.80. Note
that although the balance efficiency is the same as in the largest candidate
rule, the allocation of work elements to stations is different.
Ans 6
a= 53unit/hr, b= 46

Ans 7

a= 250units/hr, b=0.228min, c=153, d=294

Ans 8

a= 87.5min, b= .45/min, c=3.5min

Ans 9
(b) = 4, (d)= 0.218

The above mentioned problems are referred from the below text books. I am thankful
for the authors.
REFERENCES

1. Automation, Production System, and Computer Integrated Manufacturing, by Mikell

P. Groover.

2. Systems Approach to Computer-Integrated Design and Manufacturing,

by Nanua Singh.