Homework/Assignment 6

(Cellular Manufacturing)

Full Name of submitter: Nguyễn Ngọc Hân Student ID: IEIEIU18152

Your Group number is: 03

Title of your Group project is: Case study

List of team members (Student ID & Full name)

1. Trần Quỳnh Châu – IEIEIU18010

2. Nguyễn Thị Minh Hạnh – IEIEIU18165
3. Nguyễn Ngọc Hân – IEIEIU18152
4. Trương Kim Khánh – IEIEIU18037
5. Lại Thị Yến Nhi – IEIEIU18065
6. Phan Minh Thư – IEIEIU18126
7. Vũ Ngọc Bảo Trân – IEIEIU18100
8. Lê Thị Yến Vy – IEIEIU18157
1. For the following figures
Forecast

Operatin
Product Fe Ma Ap Ju Au Se
g time Jan May Jun Oct Nov Dec
s b r r l g p
(s)

17(*
A 90 17 17 17 17 17 17 17 17 17 17 17
)

B 60 30 30 30 30 30 30 30 30 30 30 30 30

C 120 40 40 40 40 40 40 40 40 40 40 40 40

D 210 20 20 20 20 20 20 20 20 20 20 20 20

(*): in thousands
a) Design assembly line(s) based on the following inputs.
- The line also can meet demand as demand goes up by 30%

1
- To avoid ergonomics issues related to repetitiveness, minimum cycle time of a workstation
is not lower than 15 seconds.
- Working time: 304 working days per year, 7 hours per day, and 2 shifts per day.
Hints
- Select a representative product.
- Design assembly lines which meet demand and use minimum resources. Fill in the below table
(please show your work as well).

1 Takt rate (required pieces per hr)  

2 Takt time (sec)  

3 Total number of operators required  

4 Total number of workstations required  

5 Number of workstations per cell  

6 Number of cells  

7 Number of operators per cell  

8 Cycle time per workstation (sec)  

9 Cycle time per operator (sec)  

10 Capacity per cell per hour (pcs/hr)  

11 Total capacity (pcs/hr)

b) If forecast increases by 20%, how many extra operators required per cell?
2. Given this precedence diagram:
Takt time = 12 min

Activity Duration (min)

A 4

B (after A) 5

C (after B) 2

2
 D (after A) 10

E (after D&C) 3

Design a line with the fewest number of workstations, highest efficiency

Note:

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Lean_HW6_G#
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---------

Answers/Works
Contribution:

Question 1: Trần Quỳnh Châu – IEIEIU18010

Nguyễn Ngọc Hân – IEIEIU18152

Lê Thị Yến Vy – IEIEIU18157

Nguyễn Thị Minh Hạnh – IEIEIU18165

Vũ Ngọc Bảo Trân – IEIEIU18100

Question 2: Lại Thị Yến Nhi – IEIEIU18065

Trương Kim Khánh – IEIEIU18037

Phan Minh Thư – IEIEIU18126

Question 1:

3
 Operating Total
Products Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
time (s) demand

A 90 17 17 17 17 17 17 17 17 17 17 17 17 204

B 60 30 30 30 30 30 30 30 30 30 30 30 30 360

C 120 40 40 40 40 40 40 40 40 40 40 40 40 480

D 210 20 20 20 20 20 20 20 20 20 20 20 20 240

Demand in thousands 1284

a) Representative product :

Product A : Running time = Demand * Operating time = 18,360,000 seconds

Product B : Running time = Demand * Operating time = 21,600,000 seconds

Product C : Running time = Demand * Operating time = 57,600,000 seconds

Product D : Running time = Demand * Operating time = 50,400,000 seconds

 Product C has the highest running time, we choose C as the Representative Product.

Annual available time = Working days * Hours per day * Shifts * Seconds

= 304 * 7 * 2 * 3600 = 15,321,600 seconds

Working time = 304 * 7 * 2 = 4,256 hours

Total demand of product family = 1,284,000 units

Takt time = Total yearly available time / Total demand of the family

= 15,321,600 / 1,284,000 = 11.93 seconds/unit

Takt rate = Total demand of products / Available working time

= 1,284,000 / 4,256 = 301.69 pieces/hours

Number of operators required = Operating time (representative product) / Takt time = 120 / 11.93 =
10,06 operators  11 operators

Number of workstations required = Total number of operators * (1 + Elasticity) = 10.06*(1+0.3) =

13.08 workstations  14 workstations
Cycle time = 15 seconds
Number of workstations per cell = Operating time (representative product) / Minimum cycle time
= 120 / 15 = 8 workstations

4
Number of cells = Number of workstations / Number of workstations per cell

= 13.08 / 8 = 1.63  2 cells

Number of operators per cell = Total number of operators / number of cells

= 10.06 / 1.63 = 6.17 operators  7 operators

Real elasticity = Number of workstations per cell / Number of operators per cell

= 8 / 6.17 = 1.3

Cycle time per workstation = Operating time / Number of workstations per cell = 120 / 8 = 15s

Cycle time per operator = Operating time / Number of operators per cell = 120 / 6.17 = 19.45 s

Capacity per cell per hour = 3600 / Cycle time per operator = 3600 / 19.45 = 185.09 pieces / hours

Total capacity per hour = Capacity per cell per hour * Number of cells = 185.09 * 1.63 = 301.7

pieces / hours

1 Takt rate (required pieces per hr)  301.69 pieces/hours

2 Takt time (sec)  11.93 seconds/unit

3 Total number of operators required  10,06 operators

4 Total number of workstations required  13.08 workstations

5 Number of workstations per cell  8 workstations

6 Number of cells  1.63 cells

7 Number of operators per cell  6.17 operators

8 Cycle time per workstation (sec)  15s

9 Cycle time per operator (sec)  19.45s

10 Capacity per cell per hour (pcs/hr)  185.09 pieces / hours

11 Total capacity (pcs/hr) 301.7 pieces / hours

b) Since the Elasticity coefficient ensure the production line still able to meet up 30% higher
in demand, therefore, no extra operators are needed.
Question 2:

5
 Activity Duration (min)

A 4

B (after A) 5

C (after B) 2

D (after A) 10

E (after D&C) 3

Total: 24

Desired cycle time = Takt time = 12 minutes

First, we draw a precedence diagram:

A B C

D E

Minimum number of Workstation:

Total completion time 24

= =2 workstations
Desired cycletime 12

Second, we group elements into workstations so that the sum of the element times at each
workstation is less than or equal to the desired cycle time of 12 minutes.

Assembly-line diagram:

6
 A, B C,D E

Workstation 1 (A,B) = 9 minutes

Workstation 2 (C,D) = 12 minutes

Workstation 3 (E) = 3 minutes

Actual cycle time = Maximum workstation time = 12 minutes

The assembly line has an efficiency:

Total completiontime 24
Effciency = = = 0.66 = 66%
Actual number of workstation × Actual cycle time 3 x 12

By traditional straight assembly-line diagram, there is no way that satisfies the condition with the
smallest number of workstation.

So, we use U-shape assembly line:

Actual cycle time = Maximum workstation time = 12 minutes

The U-shape assembly line has an efficiency:

7
 Total completiontime 24
E= = =1=100 %
Actua l number of workstation × Actual cycle time 2 x 12
This design has the fewest number of workstations, highest efficiency.