# solution

Line balancing (9 marks)

A manufacturing company sets up an assembly line that operates for 8 hours per day to produce its products. The daily demand for the products is 200 units. The tasks involved in this assembly line are listed in the table below: a) Draw the precedence diagram of this assembly line, and calculate the workstation cycle
time along with the estimated number of workstations required to achieve the demand (1
mark).

b) Balance the assembly line using the largest number of following tasks as the primary
priority rule and the longest-task-time as the secondary priority rule to achieve the
demand. Use tables to show the the number of following tasks of each task and to arrange
the tasks into workstations. Calculate the idle time of each workstation and the efficiency
of the assembly line (2 marks).

c) Re-balance the assembly line using the longest-task-time as the primary priority rule and
the largest number of following tasks as the secondary priority rule. Use a table to arrange
the tasks into workstations. Calculate the idle time of each workstation and the efficiency
of the assembly line; are they different from the one in sub-question b)? Why? (2 marks)

d) If the demand increases by 20%, apply the two strategies below to meet the new demand:
(i) Use overtime to meet the new demand using the assembly line of sub-questions b) and
c). Is the overtime different between the two assembly lines? Why? (1 mark)

(ii) Re-balance the assembly line using the longest-task-time as the primary priority rule
and the largest number of following tasks as the secondary priority rule to achieve the
new demand. Use a table to arrange the tasks into workstations. Calculate the idle
time of each workstation and the efficiency of the assembly line (2 marks).

e) Based on the individual task times, calculate the maximum output that the assembly line
can produce within the daily working hours along with the estimated number of
workstations required to achieve that output

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