Homework/Assignment 6

(Cellular Manufacturing)
Full Name of submitter: Vo Thi Thien My Student ID: IEIEIU18057
Your Group number is:
 Võ Thị Thiện Mỹ - IEIEIU18057
 Nguyễn Hoàng Anh Khôi – IEIEIU18044
 Phạm Ngọc Thu Uyên – IEIEIU18114
 Nguyễn Huỳnh Ngọc Quế - IEIEIU18073
 Trần Anh Thư – IEIEIU18160
 Lê Phương Ngọc Anh – IEIEIU18004
 Trần Thị Ngọc Vy – IEIEIU18119

Title of your Group project is: Present lecture 9: How Toyota shortened production lead time

1. For the following figures

Forecast

Operati
Produc Fe Ma Ap Ma Ju J Au Se
ng time Jan Oct Nov Dec
ts b r r y n ul 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%
- 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 shift, and 2 shifts per day.

1
 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

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---------

Answers/Works
Question 1
a)
Operating
Products Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
time (hrs)
A 0.0250 17000 17000 17000 17000 17000 17000 17000 17000 17000 17000 17000 17000
B 0.0167 30000 30000 30000 30000 30000 30000 30000 30000 30000 30000 30000 30000
C 0.0333 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000 40000
D 0.0583 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000 20000
(*): in thousands

3
 total demand
Running time of
Products of each
each product
product

A 204000 5100
elasticity 0.3

B 360000 6000 minimum cycle

15 seconds
time

C 480000 16000 Total yearly

4256 hours
available time (hr)

D 240000 14000 Total demand 1284000 units

As the running time of product C is the largest, C is the representative product. The following calculation is
done as below:

Takt rate (required 1284000/4256 = 302 pieces per

1 total demand/total yearly available time
pieces per hr) hour

2 Takt time (sec) (total yearly available time/total demand) 4256/1284000 = 11.933 seconds

Total number of 0.033/11.933 = 10.06 => 11

3 operating time of C/ takt time (hr)
operators required operators

Total number of 11*(1+0.3) = 14.3 => 15

4 total number of operators x (1+elasticity)
workstations required workstations

Number of operating time of C/minimum cycle time 0.033/(15/3600) = 8

5
workstations per cell of a workstation workstations per cell

number of workstations/number of
6 Number of cells 15/8 = 2 cells
workstation per cell
Number of operators 11/2 = 5.5 => 6 operators per
7 total number of operators/number of cells
per cell cell
Cycle time per operating time/revised number of
8 0.0333*3600/8 = 15 seconds
workstation (sec) workstations per cell
Cycle time per operating time / revised number of
9 0.0333*3600/6 = 20 seconds
operator (sec) operators per cell

4
 Capacity per cell per
10 3600/cycle time per operator 3600/20 = 180 pcs per hour
hour (pcs/hr)

Total capacity Capacity per cell per hour x number of

11 180*2 = 360 pieces per hour
(pcs/hr) cells

Real elasticity = Number of workstations per cell/ Number of operators per cell = 8/5 = 1.6
b)

total demand of Running time

Products
each product of each product
elasticity 0.3
A 244800 6120
minimum cycle 15 seconds
B 432000 7200
Total yearly
4256 hours
available time (hr)
C 576000 19200
D 288000 16800 Total demand 1540800 units

Based on the running time of each product, we still choose C as the representative product as C has the highest
running time. Thus, changes in calculation are presented as follow:

Takt rate (required 1540800/4256 = 362.03

1 total demand/total yearly available time
pieces per hr) pieces per hr
4256*3600/1540800 =
2 Takt time (sec) (total yearly available time/total demand)
9.94 seconds

Total number of 0.033/9.94 = 12.07 => 13

3 operating time of C/takt time (hr)
operators required operators

Total number of 13*(1+0.3) = 16.9 => 17

4 total number of operatorsx(1+elasticity)
workstations required workstations

Number of operating time of C/minimum cycle time of a 0.0333*3600/15 = 8

5
workstations per cell workstation workstations per cell
number of workstations/number of
6 Number of cells 17/8 = 2.125 => 2 cells
workstation per cell
Number of operators 13/2 = 6.5 => 7 operators
7 total number of operators/number of cells
per cell per cell
s

5
Hence, the extra operators per cell is 6 – 7 = 1 operator per cell.

Quesion 2: Given this precedence diagram:

Takt time = 12 min

Activity Duration (min)

A 4

B (after A) 5

C (after B) 2

D (after A) 10

E (after D&C) 3

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

AON diagram for this process:

5 2

B C
3
4
A, E
4
10

Takt time (desired cycle time) Cd = Ca = 12 minutes.

Flow time = 4 + 5 + 2 + 10 + 3 = 24 minutes
Theoretical minimum number of workstations is calculated by the equation:
j

∑ t i = 4+ 5+2+10+3 = 2 workstations. Thus, we need at least 2 workstations for this process.

N= i=1 12
cd

6
We group activities into 2 workstations as following to minimize the number of workstations and
maximize efficiency:

2
C
5
A4 B
,4 3
E

10
D

Workstation 1 Workstation 2
A, B, E  C, D
12 min 12 min
 Cycle time = 12 min
The efficiency of the line is calculated by the equation:
j

∑ t i = 4+ 5+2+10+3 = 100%
E= i=1 2∗12
Nca