A flow line mass production operation consists of eight manual workstations. Work units are moved synchronously and automatically between stations, with a transfer time of 30 sec. The manual processing operations performed at the eight stations take 40 sec, 52 sec, 43 sec, 48 sec, 30 sec, 65 sec, 53 sec, and 49 sec, respectively.
Determine
(a) cycle time for the line,
(b) time to process one work unit through the eight workstations,
(c) average production rate,and
(d) time to produce 100,000 units.

Answer:

Explanation:

Work station              Time            Transfer time

1                                  40

2                                 52                 30

3                                 43                 30

4                                 48                 30

5                                 30                 30

6                                 65                 30

7                                 53                 30

8                                 49                 30

                                380               210

The cycle time of the line = 65 seconds which is the maximum of all the times

The time to process one work unit = 380 + 210 = 590 secounds

The average production rate = 60/57 = 0.92 Pc/min

Time to produce 10000 units = 10000*0.92 = 9200 Min

= 153 hrs

= 153/8

=  19.125 days

a) The cycle time for the flow line = 590 seconds or 9.833 minutes (590/60).

b) The time to process one work unit = 590 seconds

c) The average production rate at each station = 73.75 seconds (590/8).

d) The time to produce 100,000 units = 983,300 minutes (100,000 units x 9.833 minutes).

Data and calculations:

Workstation     Time         Transfer time        Total Time

                      Taken     from each Station    Per Station

1                         40                 30                    70 (40 + 30)

2                        52                 30                    82 (52 + 30)

3                        43                 30                    73 (43 + 30)

4                        48                 30                    78 (48 + 30)

5                        30                 30                    60 (30 + 30)

6                        65                 30                    95 (65 + 30)

7                        53                 30                    83 (53 + 30)

8                       49                   0                     49 (49 + 0)

Total time      380               210                   590

Thus, the cycle time is determined as the average time between the completion of units, which is 9.833 minutes.

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