You have been asked to balance a flow shop assembly operation to achieve an output rate of 80 units per eight-hour day. Task times and precedence relationships are shown in the table below
Task Predecessor(s) Duration (minutes)
A -- 1.4
B -- 0.8
C A, B 0.4
D -- 1.8
E -- 0.4
F C 2.1
G E, F 2.0
H D, G 1.2
a. Draw the precedence diagram.
b. Determine the desired cycle time.
c. Determine the theoretical minimum number of stations needed.
d. Balance this line using the most following tasks heuristic.
e. What is the efficiency of the line obtained in part d?
The precedence diagram appears below. The desired cycle time for 80 units is 6 minutes. The theoretical minimum number of stations is 10.1/6 = 1.68 or 2.
Station Task Time (minutes) Time left (minutes) Ready tasks (#followers)
A4.,B4.,D1.,E2.
1 A 1.4 4.6 B4.,D1.,E2.
B 0.8 3.8 D1.,E2.,C3 .
C 0.4 3.4 D1.,E2.,F2.
E 0.4 3. D1.,F2.
F 2.1 0.9 D1.,G1.
2 D 1.8 4.2 G1.
G 2. 2.2 H(0)
H 1.2 1.
Summary Statistics
Cycle time 6 minutes
Time allocated (cycle time ∗ #) 12 minutes/cycle
Time needed(sum of task times) 10.1 minutes/unit
Idle time (allocated-needed) 1.900001 minutes/cycle
Efficiency (needed/allocated) 84.16666%
Balance Delay (1-efficiency) 15.83334%
Min (theoretical) # of stations 2
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