Dont Bother Me I Cant Cope

State in Line A

Supervisor :- Mr Sane.
Present Production Rate :- 315 units/day
Desired Production Rate :- 420 units/day
Estimated contribution :- Rs 30 per unit
No of workers employed :- 7
Hourly regular wage :- Rs 30 per hour

Activity
Activity Time
(Seconds)
Immediate Predecessor
1
30
None
2
50
None
3
40
1
4
50
1
5
20
2
6
10
3
7
10
4,5
8
20
2
9
10
6
10
40
9
11
20
7
12
30
7
13
50
9
14
50
10
15
10
11
16
40
8,12
Total Lead time (Sum of all activity Time) = 480

working day has 8 working hours (with rest period) gives 7 hrs working time

Cycle Time for 315 units = 420 (min) /315 units = 1.33 min/unit = 80 seconds/ unit
No of workstations required = (Production Units x Lead Time)/ Available Time
= (7 x 420)/480 = 6 Work Stations

Current Usage 315 units

Work Station
Activity
Time(Sec)
Time (Min)
Ideal Time (Min)
1
1,3
30+40=70
1.16
0.163
2
2,5
50+20=70
1.16
0.163
3
4,8
50+20=70
1.16
0.163
4
6,9,13
10+10+50=70
1.16
0.163
5
7,10,11
40+20+10=70
1.16
0.163
6
14,15
50+10=60
1
0.33
7
12,16
30+40=70
1.16
0.163
Available Time (Min) = No of Workstations x Cycle Time = 7 x 1.33 = 9.31
Ideal Time (Sum of All ideal Times above) = 1.31
Efficiency % = 8 (Rounded off from 7.95)/9.31 (Min) = 85.93

Desired Usage 420 units

Cycle Time for 420 units = 420 (min) /420 units = 1 min/unit = 60 seconds/ unit
No of workstations required = (Production Units x Lead Time)/ Available Time = 8 Work Stations

Work Station
Activities
Time (Sec)
Max Prod Capacity
(Total Sec in day /
Time per work station)
1
2
50
504
2
1,5
50
504
3
3,8
60
420
4
4,6,7
70
360
5
9,13
60
420
6
10,11
60
420
7
14,15
60
420
8
12,16
70
360

However, at workstation no 4 and 8 the total production capacity is limited to 360 and is thus bottleneck for the desired total production of 420 units per day.

Recalculating with 9 workstations

Work Station
Activities
Time (Sec)
Max Prod Capacity
(Total Sec in day /
Time per work station)
1
1
30
840
2
2
50
504
3
3,5
60
420
4
4,6
60
420
5
10
40
630
6
7,11,12
60
420
7
9,13
60
420