IE510D – APPLIED IE MODULE 2 – Problem Set 1

WORKER-MACHINE RELATIONSHIPS
1. A worker is currently responsible for tending two machines in a certain production cell.
The service time per machine is 0.35 min and the time to walk between machines is
0.15 min. The machine automatic cycle time is 1.90 min. If the worker's hourly rate is
$12/hr and the hourly rate for each machine is $18/hr, determine:
(a) the current hourly rate for the cell
(b) the current cost per unit of product, given that two units are produced by each
machine during each machine cycle. (c) What is the percentage of idle time of the
worker?
(d) What is the optimum number of machines that should be used in the cell, if
minimum cost per unit of product is the decision criterion?

2. The analyst in X Company wishes to assign a number of similar facilities to an

operator based on minimizing the cost per unit of output. A detailed study of the
facilities revealed the following:
Loading machine standard time = 0.34 minutes
Unloading machine standard time = 0.26 minutes
Walk time between two machines = 0.06 minutes
Operator rate = $12.00 per hour
Machine rate (both idle and working) = $18.00 per hour
Power feed time = 1.48 minutes
How many of these machines should be assigned to each operator?

3. A study revealed that a group of three semiautomatic machines assigned to one

operator operates 70 percent of the time unattended. Operator service time at
irregular intervals averaged 30 percent of the time on these three machines. What
would be the estimated machine hours lost per eight-hour day because of lack of an
operator?

4. In the X Company, a worker was assigned to operate three similar facilities. Each of
these facilities is down at random times during the day. A work sampling study
indicated that on the average the machines operate 60 percent of the time
unattended. Operator attention time at irregular intervals averages 40 percent. This
arrangement results in the loss of about 14 percent of the available machine time
due to machine interference. If the machine rate is P200 per hour and the operator
rate is P30 per hour, what would be the most favorable number of machines (from
an economic standpoint) that should be operated by one operator?

This study source was downloaded by 100000818583514 from [Link] on 11-06-2022 20:35:13 GMT -06:00

[Link]
 LINE BALANCING

5. Given the following operations and unit times (in hours), draw the network diagram
of the job. Develop a set of workstations that would balance the production line and
decrease idle time. Assume a cycle time of 0.05. What is the % idle time for the
unbalanced line? What is the % improvement in productive time given a balanced
line?
Element Unit Time Predecessor

1 0.0333 -
2 0.0167 1
3 0.0117 -
4 0.0167 3
5 0.0250 2
6 0.0167 4
7 0.0200 5, 6, 9, 10
8 0.0067 -
9 0.0333 8
10 0.0017 -

6. In an assembly process involving six distinct operations, it is necessary to produce

250 units per eight-hour day. The measured operation times are as follows:

A = 7.56 minutes
B = 4.25 minutes
C = 12.11 minutes
D = 1.58 minutes
E = 3.72 minutes
F = 8.44 minutes

How many operators would be required at 80 percent efficiency? How many

operators will be utilized at each of the six operations?

TIME STUDY

7. The following data resulted from a study taken on a horizontal milling machine:
Pieces produced per cycle: 8
Average measured cycle time: 8.36 minutes.
Average measured effort time per cycle: 4.62 minutes.
Average rapid traverse time: 0.08 minutes.
Average cutting time power feed: 3.66 minutes.
Performance rating: 115 percent.
Allowance (machine time): 10 percent.
Allowance (manual time): 15 percent.

This study source was downloaded by 100000818583514 from [Link] on 11-06-2022 20:35:13 GMT -06:00

[Link]
 The operator works on the job a full eight-hour day and produces 380 pieces.
How many standard hours does the operator earn? What is her efficiency for the
eight-hour day?

8. Establish the money rate per hundred pieces from the following data:
Cycle time (averaged measured time) : 1.23 minutes.
Base rate: $ 8.60 per hour
Pieces per cycle: 4.
Machine time (power time): 0.52 minutes per cycle.
Allowance: 17 percent on effort time;
12 percent on power feed time.
Element 1 average time: 0.09 minutes.
MTM time for element 1: 132 TMU. (One TMU = 0.00001
hour)
Plant uses synthetic performance rating.

9. In the XYZ Company, management is considering going from two 8-hour shifts per
day to three 8-hour shifts per day or two 10-hour shifts per day in order to increase
capacity. Management realizes that shift start-up results in a loss of productivity that
averages 0.5 hour per employee. The premium for the third shift is 15 percent per
hour. Time over eight hours worked per day gives the operator 50 percent more pay.
To meet projected demands, it is necessary to increase the work-hours of production
by 25 percent. In view of insufficient space and capital equipment, this increase
cannot be accommodated by increasing the employees on either the first or the
second shift. How should management proceed?

10. For a certain repetitive task, the snapback timing method was used to obtain the
average work element times and performance ratings listed in the table below.
Elements a, b, and c are worker-controlled. Element d is a machine-controlled
element and its time is the same each cycle (N.A. means performance rating is not
applicable). Element c is performed while the machine is performing its cycle (element
d). Element e is a worker-controlled irregular element performed every five cycles.
The machine is idle during elements a, b, and e. One part is produced each cycle. The
machine allowance is 15%, and a 15% PFD allowance is applied to the manual
portion of the cycle. Determine (a) the normal time and (b) the standard time for this
cycle. If the worker’s performance during actual production is 130% on all manual
elements for 7.3 actual hours worked on an eight hour shift, (c) how many units will be
produced and (d) what is the worker’s efficiency?
Work element a b c d e
Observed time 0.47 0.58 0.70 0.75 2.10
(min)
Performance 90% 80% 110% N.A. 85%
rating

This study source was downloaded by 100000818583514 from [Link] on 11-06-2022 20:35:13 GMT -06:00

[Link]
 11. For a worker-machine task, the continuous timing method was used to obtain the
times indicated in the table below. Element c is a machine-controlled element and the
time is constant. Elements a, b, d, and e are operator-controlled and were perfor-
mance rated at 100%; however, element d is performed simultaneously with element
c. The machine allowance is 16%, and the PFD allowance is 16%. Determine (a) the
normal time and (b) standard time for the cycle. (c) If the operator works at 140% of
standard performance in production and two parts are produced each cycle, how
many parts are produced if the total time worked during an 8-hour day is 7.4 hours?
(d) For the number of parts computed in (c), what is the worker’s efficiency for this
shift?
Element a b c d E
Observed time (min) 0.30 0.65 1.65 1.90 2.50

WORK SAMPLING

12. The ABC Co. provides a 10% allowance for its operators. A work sampling study of
one operator over an 8-hour shift yields the data as follows: Load = 16 observations;
Unload = 14 observations; Clean and service = 7 observations; Idle = 13
observations. Average rated performance is 110%. a) What is the observed time
(in min.) for loading?; b) What is the normal time (in min.) for unloading?; c) What is
the overall standard time (in min)?; d) What is the accuracy of the study?

13. A work sampling study was performed on 15 social workers in a county government
office. The social workers handle three types of cases: A, single parents; B, foster par-
ents; and C, juvenile delinquents. The purpose of the work sampling study was to de-
termine estimates of the average time per case for each case type. In addition to the
three case types, two additional activity categories were included in the study: D, trav-
eling between cases; and E, other (miscellaneous) activities. The study was carried
out over a five-week period (25 8-hour days or 200 working hours). Observations were
taken at random times four times each day for 25 days, for a planned total of 1500 ob-
servations (4 x 25 x 15). Each social worker was provided with a cell phone so they
could be contacted if they were not in the office building. Because of worker ab-
sences, 72 observations were omitted (18 worker-days of absences). Results of the
study are presented in the table below. (a) What is the mean time per case for each of
the three case types? (b) For the C type cases, construct a 92.5% confidence interval
about the mean case time.
Category of activity A cases B cases C cases D E Other
Transport
Number of observations 314 272 350 388 104
Number of cases 439 725 273 (none) (none)
completed

This study source was downloaded by 100000818583514 from [Link] on 11-06-2022 20:35:13 GMT -06:00

[Link]
 14. Burger Haus prides itself on fast service. To be able to do this, it provides only one
type of food service: The Combo – a regular coke, a hamburger with everything on
it and regular fries. A work sampling study performed on the cook of one of its
branches over an 8-hour shift found the following results. The day’s receipts
indicated that 200 combos had been sold at P35.00 each. What is the standard time
for making the combo? If you desired an accuracy of 0.1 min. on the standard time
for the combo, how many observations should have been collected?

Idle Rating Filling Cokes Making Hamburger Frying Fries

IIII 110 lIIII I IIII IlIII I

IIII 100 IlIII I lIIII II IIII

II 90 IIlII III IlIII I IIlII II

Relaxation Allowances 9% 11% 11%

LEARNING CURVE

15. A student in Methods Engineering Laboratory is asked to assemble a lego toy 6

times. He completed the 1st assembly in 30 minutes and the 2nd in 24 minutes. A)
What is his learning rate? B) If this same rate continues, how long will the 3 rd
assembly take? C) How long will it take the student to assemble the lego 6 times?

This study source was downloaded by 100000818583514 from [Link] on 11-06-2022 20:35:13 GMT -06:00

[Link]
Powered by TCPDF ([Link])