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Optimizing Production Line Efficiency and Workstation Balancing

This analysis addresses the line balancing problem with various task times and aims to determine the bottlenecks, maximum production rates, and efficiency levels. Key questions explored include identifying the bottleneck station, calculating maximum production per hour, assessing efficiency and balance delays, and minimizing the number of workstations. The efficiency scores for different configurations reveal the effectiveness of each layout, contributing to a solution that optimizes production while maintaining target performance levels.

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Optimizing Production Line Efficiency and Workstation Balancing

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  1. Line Balancing Problem 3.4 mins B E 2.7 mins 2.2 mins A C 4.1mins D 1.7mins F 3.3 mins G 2.6 mins

  2. Questions? 4.1 minutes • 1. What is the bottleneck? • 2. What is maximum production per hour? 60/4.1=14.63 units • 3. What is efficiency and balance delay? • 4. How to minimize work stations? • 5. How should they be grouped? • 6. New efficiency?

  3. Calculate efficiency • A. 73.2% • B. 56.7% • C. 69.7% • D. 79.6% • E. 81.2% 3.4 mins B E 2.7 mins 2.2 mins A C 4.1mins D 1.7mins F 3.3 mins G 2.6 mins

  4. (2.2+3.4+4.1+2.7+1.7+3.3+2.6) 4.1x7 20 28.7 69.7% 1-69.7%=30.3% Balance Delay

  5. Number of Work Stations (bottleneck) 20 4.1 = 4.88 work stations

  6. 4 Stations 20/24=83.3% Line Balancing Solution Max prod./hour 60/6 10 units/hour (5.6) 3.4 Station 3 B Station 1 E 2.7 2.2 A C 4.1 (6.0) Station 2 Station 4 (5.8) D 1.7 F 3.3 G 2.6 All under 6 minutes?

  7. 5 Stations Line Balancing Problem 3.4 mins 20/5.6x5 = 20/28 = 71.4% 5.6 B E 2.7 mins 2.2 mins A C 4.1mins Max Prod./hour 60/5.6 10.7 units/hour D 1.7mins F 3.3 mins G 2.6 mins 5.0

  8. What is the minimum # of work stations? Round down. 40 secs 59 secs 34 secs 84 secs • 3 • 2 • 4 • 5 • 6 56 secs 45 secs

  9. 40+59+84+56+34+45 = 318 318/84 = 3.78 or 3 work stations What is the efficiency with 6 operators? 318/6 x 84= 318/504 = 63%

  10. 99 secs 3 Stations ? 40 secs 118 secs 59 secs 34 secs 84 secs 318/3x118 318/354 = 89.8% 56 secs 45 secs 101 secs

  11. 99 secs 4 Stations? 40 secs 84 secs 79 secs 59 secs 34 secs 84 secs 56 secs 318/4 x 99 = 318/396 = 80.3% 45 secs 56 secs

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