Problem Answers

Chapter 10
1. Required cycle time = 1 minute / unit
Whether the cell should be developed for that cycle time depends upon the
accuracy of the forecast.
2. (a) Required CT for part A = 90 sec /unit
(b) Required CT for part B = 64 sec / unit
The required minimum production capacity of the process is 450 units per
day.
3. Worker 1 CT = 323 sec / unit and worker 2 CT = 392 sec / unit, thus the
cycle time for the process is 392 sec / unit.
(a)

Required daily capacity = 70.24 or 71 units

(b)

Since the CT of the process is < Required CT (410 sec), the

workcell has adequate capacity.

4. (a)

Time to produce 71 units

For worker 1, 392 sec / unit (71 units) = 27, 832 sec
For worker 2, 323 sec / unit (71 units) = 22, 933 sec
Assuming an 8-hour day for both workers, available labor time =
57,600 sec. This results in 6835 sec of idle time or about 11.9%.

(b)
5. (a)

(b)

73.46 units
Cycle time would be the same as the slowest worker, 15 min.
With 3 workers cycling around the cell the average cycle time
would be 5 min / unit.
In 15 minutes one worker gets one unit
In 15 minutes one worker gets 15 / 14 =1.07 units

In 15 minutes one worker gets 15 / 13 = 1.15 units

Therefore, in 15 minutes three workers would get 3.22 units and
the CT = 15 minutes / 3.22 units = 4.66 minutes / unit.
6. (a)

Since the manual time at station 5 is now only 10 sec, the cell CT is
reduced by 30 sec to 421 sec / unit.

(b)

The manual times at stations 7 and 8 are each reduced by 70

seconds, so the cell CT is reduced by 140 seconds to 451 140 =
311 sec / unit

(c)

Discussion question. To be addressed in class.

See last page for additional information

problem #7.
7. (a)

Worker
Worker
Worker
Worker
CT
CT
CT
CT

1
2
3
4

has
has
has
has

(worker
(worker
(worker
(worker

before beginning work on

incoming outgoing material and operations 1 and 8.

operations 2 and 7
operations 3 and 6
operations 4 and 5

4)
3)
2)
1)

=
=
=
=

90 + 18 = 108 sec / unit

60 + 27 = 87 sec / unit
130 + 27.5 = 157.5 sec / unit
120 + 25.5 = 145.5 sec / unit

Therefore, CT = 157.5 sec / unit

Daily Capacity = (480 min / day x 60 sec / min) / 157.5 sec / unit
= 182.9 units
(b)

worker
worker
worker
worker
worker
worker

1
2
3
4
5
6

has
has
has
has
has
has

incoming and station 1

station 2
station 3 and 4
station 5 and 6
station 7
station 8 and outgoing

worker 1 CT = 40 + 8 = 48 sec / unit

worker 2 CT = 50 + 9 = 59 sec / unit

worker 3 CT = 21 + 70 = 91 sec / unit
worker 4 CT = 17 + 80 = 97 sec / unit
worker 5 CT = 9 + 80 = 98 sec / unit
worker 6 CT = 9.5 + 80 = 89.5 sec / unit
Therefore CT = 97 sec / unit
Daily Capacity = (480 min / day x 60 sec / min) / ( 97 sec / unit) =
= 296 units
(c)

Four workers
Labor cost = $80 / hr ; CT = 157.5
Cell Output Rate = 22.86 units / hr
Unit cost = $7.00 per unit
Six workers
Labor cost = $120 / hr
Cell Output Rate = 37.11 units / hr
Unit cost = $ 5.39 / unit
Comparing these costs with the costs given in the chapter , the lowest
cost case is for four workers.

8.

Refer to problem 7a for worker assignments.

Worker
1
2
3
4

Setup
2(10)
2(10)
2(10)
2(10)

Walk
25.5
27.5
27
18

CT (sec)
45.5
47.5
47
38

Longest
mach.
Run+SU

80
80
40
50

Subcell CT
(sec)
80
80
47
50

Therefore, cell CT = 80 sec / unit

Daily Capacity = (480 min /day x 60 sec / min) / (80 sec / unit) = 360 units

(c)

Dividing the workcell among five workers to reduce the cell CT to at

least 40 sec / unit requires additional machines at stations 2, 4, 7,
and 8

Worker

Setup

Walk

CT

Longest
run + SU
1
2(10)
16.5
36.5
50/2 = 25*
2
2(10)
16.5
36.5
50/2 = 25*
3
2(10)
12
32
40
4
10
16
26
80/3=
26.7*
5
10
16
26
80/3 =
26.7*
*Denoted multiple machines visited on an alternating basis.

Subcell CT
(sec)
36.5
36.5
40
26.7
26.7

Therefore, cell CT = 36.5 sec / unit

Daily Capacity = (480 min /day x 60 sec / min) / (36.5 sec / unit) = 789 units
9.

Assume the walk times between stations are as shown in Figure 10.7.
The operation times shown are for one unit. Assume items are processed
in batches of 6 units at a time, and allow 3 seconds handling for each unit
at each station.
Time for worker to complete one cycle around the cell
= (operation time at 8 stations ) + walk times
= [400 sec + 8 (3 sec)] (6 units) + 51 sec = 2595 sec
CT = [2595 sec / batch] / [6 units / batch] = 432.5 sec / unit

10.

Worker CT = setup times + walk time = 134 + 60 = 194 sec

CT
CT
CT
CT

(A) = 175
(B) = 204
= 227
(D) = 218

Therefore, machine C controls the overall cycle time with 227 seconds.
4

11.

Add 2 seconds to machine operating time to allow for loading- unloading

between parts:

Divide the setup time of each machine by 20 to determine how much the
overall cycle time will be increased.
Machine
Operation Time
(sec/unit)

A
154

23/20 = 1.15
155.15
The walk time and the
Total CT

B
175

C
177

D
192

31/20 = 1.55
176.55

52/30 = 2.60
179.60

28/20 = 1.4
193.4

For single unit production (problem 10a)

Daily Capacity = [480 min/day x 60 sec/min] / [227 sec unit] = 126.9 units
For 20-unit batch production:
Daily Capacity = [480 min /day x 60 sec / min] / [193.4 sec / unit] = 148.9
units
Notice that batching does not greatly reduce the cell CT because the manual
(setup and walk) times and the longest machine unit-operating times are close
in value. When the unit operating times are much smaller than the manual
times, however, then batching significantly reduces cell CT.

Times used in moving in problem #7