Chapter 8: Material Flow Analysis and Facility Layout Prior to attempting these problems, you should try to solve #5, 9, 11 and 13 in the text. The answers for these problems are in the back of the book. M5_P1. The process design team at a Sylva Manufacturing has broken an assembly process into 8 basic steps, each with a required time and predecessor, as shown in the table. There are 7.5 productive hours available in a day, and the Sylva wishes to produce 400 units. Immediate Predecessors Task A B C Time (sec) 45 50 20 55 15 65 25 35 A A A D E D F D G . E B, C, F, G a) What should their takt time be? b) What is the theoretical minimum number of stations? c) Operations managers and process engineers design a line that contains 6 stations. What is the efficiency? d) Operations managers and process engineers design a line that contains 6 stations. What is the percentage of idle time? e) The managers decide to balance the line by assigning tasks to workstations to fill up as much task time as possible. Break ties by assigning the longest task first. What task(s) should be assigned at the third workstation