Name:
Period:
Date:
Production Scenario
A four-station line assembles small emergency flashlights. One worker is assigned to each station. The line can only move as fast as its slowest station.
| Station | Tasks | Time per unit |
|---|---|---|
| 1 | Install battery contacts and wiring | 42 seconds |
| 2 | Install switch and LED module | 68 seconds |
| 3 | Close housing and install four screws | 55 seconds |
| 4 | Function test, label, and package | 35 seconds |
1. Analyze the Current Line
- Which station is the bottleneck?
- What is the line cycle time?
- Approximately how many units can the line produce in one hour? Use 3,600 seconds per hour.
- Which station has the most idle time each cycle?
2. Task Details
| Task | Time |
|---|---|
| Install battery contacts | 22 s |
| Connect wiring | 20 s |
| Install switch | 28 s |
| Install LED module | 40 s |
| Close housing | 15 s |
| Install screws | 40 s |
| Function test | 20 s |
| Label and package | 15 s |
3. Rebalance the Line
Reassign tasks among four stations. Each task must remain intact and every unit must complete all tasks.
| New station | Assigned tasks | Total time |
|---|---|---|
| 1 | ||
| 2 | ||
| 3 | ||
| 4 |
4. Evaluate the Improvement
- What is the new bottleneck time?
- What is the new estimated hourly output?
- How many additional units could be produced in an eight-hour shift?
- What practical problem might make your plan difficult to implement?
5. Recommendation
Write a short recommendation describing the bottleneck, your change, and the expected production improvement.
Submission Checklist
- All analysis questions are answered.
- Required calculations, tables, sketches, or diagrams are complete.
- The final recommendation uses evidence from the lesson.
- Your name, class period, and date are included.
Closing Reflection
What was the most important engineering or manufacturing decision you made in this lesson? Explain why it mattered.