1. You are assigned to redesign an existing assembly line into a cell. The sales history shows the demand for the product to be 960 units per day. Your cell is intended to operate 16 hours per day. The task times (seconds) and precedence are shown below. (5 pts)
Determine Takt Time
Calculate the theoretical minimum number of operators.
Create a balance chart showing each operator and the tasks assigned to each person.
Make an outline of the cell layout indicating what tasks are assigned to each workstation. Only assign one workstation to each person.
How much time would need to be eliminated to remove a person from the operation?
2. You have implemented the cell in Problem 1. It is quickly evident that your design does not meet the daily demand. You have collected data and realize that you are approximately 10% below the target due to quality issues, breakdowns and other minor stoppages. The Value Stream Leader demands that you boost production by rebalancing the line using a faster Planned Cycle Time (PCT) (5 pts)
Determine the new Planned Cycle Time (PCT = Takt * OEE).
Calculate the theoretical minimum number of operators if running at PCT.
Create a balance chart showing each operator and the tasks assigned to each person. Did you have to add a person? Why or why not?
Make an outline of the cell layout indicating what tasks are assigned to each workstation.
How much would OEE need to be increased to eliminate an operator?
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