Batch Process/Assembly Line

Rohit Kapoor

Characteristics of Batch Process

Make to stock environment (demand is relatively stable). Sometimes dealing with multiple products. Goods produced in discrete batches/lot sizes. Process flow more or less routine. Little or no variability in product selection known in advance

Batch Process
Key Issues in Managing Batch Process

Planning & Forecasting Determining batch sizes Capacity management

Capacity is limited here.

Shop floor synchronization Worker incentives

Assembly Line

Illustration 1
A production line operating 450 minutes per day is to have an output of 250 units per day. Find the cycle time.

Illustration 2
The precedence diagram for assembly activities A through H is shown below, with the element time requirements shown in minutes. The line operates 7 hours per day, and an output of 600 units per day is desired. Compute cycle time and (b) the theoretical minimum number of stations.

Illustration 3
Using the data and precedence diagram from Illustration 2 (a) group the assembly-line tasks into an appropriate number of workstations using the longest work-time rule, and (b) compute the balance efficiency and (c) the idle time.

Illustration 4
Suppose the activities shown in Fig.A are to be grouped into a three-station assembly line. (I)What is the target cycle time? (II) Which grouping of activities results in the largest output per hour? (III) What output will result in a 7 -hour day?

Illustration 5
Tasks A through I have the predecessor and time requirements shown in Table. Output is to be 200 units per day, and operating time is 450 minutes per day. Using the most successors rule to assign tasks to work centers, and the longest work-time rule as a tie breaker, (0) group the tasks into work centers, WCs, and compute (b) the balance efficiency, (c) the idle time, and (d) the balance delay.
Task A B C D E F G H I Predecessor None A None C D None F G H Time (see) 40 20 60 40 30 35 45 60 40

 An electric appliance assembly area is as shown in Fig. A with potential workstations A through F. The tasks that must be done, along with their respective times, are indicated in the precedence diagram, Fig. B The machine scan is automatic and can come any time after task 2. The manufacturer desires an output of 367 units per 8-hour day and stops the line for a 20-minute break in the middle of the morning and the afternoon. (a) Group the assemblyline tasks into appropriate workstations using the longest time rule, and (b) compute the balance efficiency. Fig. A Fig. B

 Overland Motors produces 50 cars per hour (Fig. C) and has a transmission feeder shop with three workstations (A, B, C), which take times of 55, 45, and 60 seconds, respectively. Station C assembly time is normally distributed, with a standard deviation of 5 seconds. (a) If all work arrived at C on time, what proportion of the time would the feeder shop fail to deliver transmissions on time to the main auto assembly line? (b) What is the balance efficiency for the transmission feeder shop? Fig. C

 Robotic Controls Corp. uses a robotic-controlled flexible production system to assemble the robots it sells. Five robots are available and must complete the tasks specified in Table.
Table Time Task A B C D E F G H I J K L (sec) 10 24 17 49 12 14 27 9 20 23 36 18 Preceding Task(s) None None A A C C 8 E F, G D, H, I I J, K

(a) Draw a precedence diagram. (b) What is the theoretical minimum (target) cycle time if all five robots are fully utilized in a five-station assembly line? (c) Group the tasks into the most efficient five-station assembly line. (d) What is the cycle time? (e) What is the balance efficiency?