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The Mach 10 is a one-person sailboat manufactured by Creative Leisure. The final assembly plant is in Cupertino, California. The assembly area is available for production of the Mach 10 for 200 minutes per day. (The rest of the time it is busy making other products.) The daily demand is 60 boats. Given the information in the table,

a) Draw the precedence diagram and assign tasks using five workstations.

b) What is the efficiency of the assembly line, using your answer to (a)?

c) What is the theoretical minimum number of workstations?

d) What is the idle time per boat produced?

 
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Tailwind, Inc., produces high-quality but expensive training shoes for runners. The Tailwind shoe, which sells for $210, contains both gas- and liquid-filled compartments to provide more stability and better protection against knee, foot, and back injuries. Manufacturing the shoes requires 10 separate tasks. There are 400 minutes available for manufacturing the shoes in the plant each day. Daily demand is 60. The information for the tasks is as follows:

a) Draw the precedence diagram.

b) Assign tasks to the minimum feasible number of workstations according to the “ranked positioned weight” decision rule.

c) What is the efficiency of the process you completed in (b)?

d) What is the idle time per cycle?

 
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Dr. Lori Baker, operations manager at Nesa Electronics, prides herself on excellent assembly-line balancing. She has been told that the firm needs to complete 96 instruments per 24-hour day. The assembly-line activities are:

a) Draw the precedence diagram.

b) If the daily (24-hour) production rate is 96 units, what is the highest allowable cycle time?

c) If the cycle time after allowances is given as 10 minutes, what is the daily (24-hour) production rate?

d) With a 10-minute cycle time, what is the theoretical minimum number of stations with which the line can be balanced?

e) With a 10-minute cycle time and six workstations, what is the efficiency?

f) What is the total idle time per cycle with a 10-minute cycle time and six workstations?

g) What is the best workstation assignment you can make without exceeding a 10-minute cycle time, and what is its efficiency?

 
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Suppose production requirements in Solved Problem 9.2 increase and require a reduction in cycle time from 8 minutes to 7 minutes. Balance the line once again, using the new cycle time. Note that it is not possible to combine task times so as to group tasks into the minimum number of workstations. This condition occurs in actual balancing problems fairly often.

Problem 9.2

A Missouri job shop has four departments— machining (M), dipping in a chemical bath (D), finishing (F), and plating (P)—assigned to four work areas. The operations manager, Mary Marrs, has gathered the following data for this job shop as it is currently laid out (Plan A).

It costs $0.50 to move 1 workpiece 1 foot in the job shop. Marrs’s goal is to find a layout that has the lowest material handling cost.

a) Determine cost of the current layout, Plan A, from the data above.

b) One alternative is to switch those departments with the high loads, namely, finishing (F) and plating (P), which alters the distance between them and machining (M) and dipping (D), as follows:

What is the cost of this layout?

c) Marrs now wants you to evaluate Plan C, which also switches milling (M) and drilling (D), below.

What is the cost of this layout?

d) Which layout is best from a cost perspective?

 
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