Question

12. The production of auto component goes through the processes of parts production, assembly, inspection and packaging. The time of each process is indicated in the diagram below (10 points)

Part Production 100 units/30min

Assembly Unit 100 units/20mins

Inspection Unit 100units/10mins

Packaging Unit 100 units/15min

a. What is the cycle time of the process?

b. What is the manufacturing lead time of each batch of 100 parts?

c. If the work is carried out as indicated above

(i) What would be the idle time of each process, if any, during the second batch production?

(ii) Between which consecutive processes would there be work-in-process, if any?

d. Is the line balanced? If not, how will you balance the line?

Answer 1

a) Time required for one unit to pass the process is cycle time.

Now total time required for 100 unit batch = 30 + 20 + 10 + 15 = 75 minutes

time required for 1 unit = 75 / 100 = .75 minutes

so, cycle time is = .75 minutes

b) Total time it takes to pass the process is the lead time.

lead time = 30 + 20 + 10 + 15

= 75 minutes

c)

(i) idle time of each process, during the second batch production:

parts production units is = 0 minutes (since it is the first process)

assembly unit = 30 min - 20 min = 10 min

inspection unit = 30 - 10 = 20 min

packaging unit = 30 min - 15 min = 15 min

(ii) Because of there is ideal time at each process, work in process between any process is 0

d) First of all line is not balanced, so to balance the line, the best thing is to perform assembly and inspection at single workstation, by this ideal time will reduce because of total process time of new process

that would be = 20 + 10 = 30 min

By this ideal time will be 0 and then the line will balanced