Problem 1: Line Balancing

First shift employees at GE Applianceswork from 2pm-10pm Monday through Friday assembling washing machines. Everyone on the assembly line is allowed a 30 minute lunch and two15 minute breaks. The assembly line stops while associates are on lunch or break. The processes of the assembly line have the following dependencies:

Task                      Predecessor                      Average Time (sec)

A                            none                                    30

B                            none                                    15

C                            A                                           20

D                           B                                           15

E                            D                                          10

F                            E                                           10

G                           C, F                                      30

The Plant Manager needs first shift to achieve an output of 600washing machines each day.

Compute the Takt time for the line.

What is the theoretical minimum number of workstations?

Draw the precedence diagram, and then create work stations. Follow the “most following tasks”heuristic ruleto assign these tasks to the work stations. Show which tasks are assigned to each workstation.

Compute the efficiency and percent idle time for the system.

What is the maximum output that could be achieved by a single assembly line in 7 hours?