1.1. Please draw rectangular shapes to group tasks that belong to one workstation. You can draw directly on the diagram. 1.2. Based on your grouping above, please list work elements for each workstation.

Work Station 1	Work Station 2	WS 3	WS 4

1.3. Based on your grouping above and the cycle time of 72 seconds, what is the sum of task time for the line you have created?

1.4. Based on your grouping above and the cycle time of 72 seconds, what is the total amount of idle time in this production line you have created?

1.5. Based on your grouping above and the cycle time of 72 seconds, what is the efficiency of this production line you have created?

1.6. What is the effective cycle time of the production line you have created?

Challenge 2: A Line Balancing Problem SALES DATA

Use the data provided to answer questions 2.1 through 2.3.

These are the sales figures for the TX-750 calculator. Calculators are sold every day of the month but are only produced at the factory 5 days per week, Monday through Friday.

LINE BALANCING - PRECEDENCE DIAGRAM The following precedence diagram gives the necessary data to answer the line balancing-related questions.

2.1 What is the 4-Period Simple Moving Average Forecast for Period 13?

2.2 Since the demand seems to be fairly stable over the 12-month period, is the 4-Period Simple Moving Average Forecast a good forecasting model to use?

2.3 If we assume an average of 22 working days per month in the factory, how many calculators will need to be produced per day in the factory if we use a 4-Period Simple Moving Average Forecast for Period 13?

LINE BALANCING 2.4 What is the CYCLE TIME that ensures the desired output rate? Please round down to a whole number. (NOTE: NEVER ROUND UP YOUR CYCLE TIME!!! YOU should be able to figure out why this should never be done.)

USE the number you round down to in all of your calculations.

Use the numbers calculated in questions 2.1 through 2.4 to complete question 2.5. Remember, the factory is open 22 days per month. The assembly line runs 8 hours per day.

2.5 What is the theoretical minimum number of workstations? Please round up to a whole number. (ALWAYS ROUND UP workstations. Again, you should know why.)

2.6 Design the line. Use as few workstations as needed. Try to get close to your Theoretical minimum number of workstations calculated. Remember to maintain your precedence relationships and abide by your calculated cycle time.

2.7 What is the efficiency of the line you created in question 6? (Show 4 decimal places). Use the cycle time calculated in question 4.

2.8 What is your calculated IDLE TIME for the line you created in question 6? Does it match up with the number you listed as the Total Idle Time for the line you created in question 6?

2.9 What is the EFFECTIVE CYCLE TIME of the line you created?

Challenge 3: Observe a Real-Life Production/Service Line ( Please observe a production or service line (for example, in Subway, Chipotle, Baha Fresh, or a local Cafeteria) and perform the following tasks:

3.1 Please break down and describe each task that needs to be carried out in order to produce the final product/service item. Please include the identification of the task (i.e., name it), the duration of the task, precedence rules, and the number of employees currently performing these tasks. (4 Points)

3.2 Based on your answers above, please build a precedence diagram. Make sure you depict each task, its duration, and precedence rules.

3.3 How are the tasks divided currently? (Please present your results in a table format, similar to the table in Challenge 3.6). What is the effective cycle time in this production line? What is the utilization rate of the production line?

3.4 Are there an alternative way(s) to balance the production/service line? If so, please document your alternative design(s). Are these alternative approaches better or worse than the current approach? Why?

Please discuss in terms of the even division of work and effective cycle time.

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