line balance

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Instructions and other info

Additional facts
	Each of the four lines are configured and staffed the same way with the same machinery and % utilization. Lines 1 and 2 are in the same part of the plant and from centerline to centerline are 40 feet apart. Trays can be loaded from either side of the line and from the front end of the line. Carton and film machines and case packers can be left or right handed machines meaning they can both be fed between the lines. Component placers are split with two on each side of line. There are cross overs ~every 30 ' to move from one side of the line to the other. Lines 3 and 4 are configured in this same manner but are located approximately 150' from Lines 1 and 2. Job combinations can occur in several different ways.
	1. Jobs can be eliminated entirely with proper justification but must be supported by facts
	2. Jobs can be combined within the same line.
	3. Jobs can be combined between Lines 1 and 2 or Lines 3 and 4. Assume if Line 1 and 2 can combine so can Lines 3 and 4
	4. Jobs can be combined between three or four lines.
	At no time can an employee be utilized over 100%. When moving within a line assume .5 seconds per foot traveled. If you move 10 feet the travel time would be 5 seconds to new location and 5 seconds return. When traveling between two adjacent lines this also applies. If you must change out gloves assume one minute and if you must change uniform assume 3 minutes. If you move from the Line 1 and 2 area to Line 3 and 4 area assume a minimum of three minutes travel time each way. If a cross over is needed asume an additonal 30 seconds in additon to the time per foot.
	When calculating savings assume each line runs 250 shifts per year on 1st shift and 250 shifts per year on second shift. Total of 2000 annual shifts. Assume an average hourly rate per employee is $17.50 per hour with a fringe rate of of 150%.
	The video from class on April 12 is available in D2L under videos and goes into greater detail on the different jobs involved. The video from the April 14 will also be helpful and will include more information needed to calculate savings.
	Items in yellow on spreadsheet are the jobs that I would consider for combination. Not all of these jobs will prove to be feasible. The expectation for savings is between $600,000 and $1,300,000. This does not mean you cannot consider the other jobs but do not make an assumption that a job could be automated or all rejects can be eliminated, etc.
	Items in green indicate items where the verbiage changed slightly from the original numbers

Line 1

Job #	Job title	Job description	% Utilization	Frequency	Distance from Tray denester (front of line)	Special Notes	Hours worked per day
1	Lead person	Directs employees, gives breaks, orders supplies and any other tasks as needed	100%		varies	Can be used to fill short term emergency vacancies	9
2	Tray machine operator	Feeds trays into denester	33%	Feeds trays once every 3 minutes. One minute to completely reload the magazines. Can be topped off at any time	1 '	Cannot handle food products without changing gloves	8.2
3	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
4	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
5	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
6	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
7	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
8	Component placer	Adds component to tray	82%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
9	Inspect for missing component	Add to or remove trays with missing components	80%		37'	Cannot change lines without changing uniform	8
10	Line Service	Provides materials to the line in various places	80%	varies constantly during shift	2' to 56'		8.5
11	Line Service	Provides materials to the line in various places	80%	varies constantly during shift	2' to 56'		8.5
12	Film machine operator	Reloads film spindle, splices onto existing roll, removes doubles from splice, rotates spindle, removes spent roll, discards spent roll.	38%	It takes 3 minutes to perform duties every 8 minutes. The actual splicing and changing of the roll takes 45 seconds and the rest of the time is in set up and support fuctions The total of 3 minutes does not have to occur consecutively. Once the splice is made, the rejects created can be dealt with immediately or before the next splice is made. removal of the old roll and reloading the new roll on the spindle works the same way.	45'	Cannot handle food products without changing gloves	8.2
13	Film machine inspector	Looks for loose seals and removes as needed	90%	varies constantly during shift	49'		8
14	Carton machine operator	Reloads flat cartons into machine	20%	30 seconds to reload every 150 seconds. Machine can be topped off at any time. The magazine does not have to be completely empty.	56'	Cannot handle food products without changing gloves	8.4
15	Final inspector	Removes open, unsealed or damged cartons	60%	varies constantly during shift	61'		8.4
16	Wgt control	Continually monitors weights of product, adjusts machine settings as needed, produces control charts for 6 sigma program	75%		varies	Can be used in an emergency but every minute this job is unfilled it costs you money	8.4
17	Quality Control inspector	Checks component weights every 60 minutes, total weights every 20 minutes and verifies day coding information every two hours. Maintains the official USDA complance records for weight	42%		varies	Must be HACCP certified and tasks are required by law
18	Maintnenance person	Monitors the line, makes repairs and adjustments as needed	95%		varies	Do not combine with anything	9
19	Case packer operator	Feeds blank cases into case packer, changes out pallets of blanks	33%	Feeds blanks for 1 minute every 3 minutes	90'	The line produces a maximum of 24 cases per minute	8.2
20	Case stacker	Stacks finished cases onto a CHEP pallet	55%	Stacks one case every 5.5 seconds. Capable of 20 cases per minute	112'	Can backlog cases for ~ 30 seconds without issue	8.4
21	Case stacker	Stacks finished cases onto a CHEP pallet	55%	Stacks one case every 5.5 seconds. Capable of 20 cases per minute	112'	Can backlog cases for ~ 30 seconds without issue	8.4
22	Remove to warehouse	Takes finished pallet to freezer	95%	One pallet every 3 minutes	120' to 275'	Reports to warehouse	8.3
23	Prep employee	Prepares product for line in remote location	80%		225'	Loads the system at the beginning of shift and adjusts for zero run out at shift end	9.5
24	Prep employee	Prepares product for line in remote location	80%		120'	Loads the system at the beginning of shift and adjusts for zero run out at shift end	9
25	Prep employee	Prepares product for line in remote location	80%		90'	Loads the system at the beginning of shift and adjusts for zero run out at shift end	8.5
26	Reject worker	Reworks or dumps product removed from line	75%		50"	Varies by product. Can be used on other lines if demand is there	8

Line (2)

Job #	Job title	Job description	% Utilization	Frequency	Distance from Tray denester (front of line)	Special Notes	Hours worked per day
1	Lead person	Directs employees, gives breaks, orders supplies and any other tasks as needed	100%		varies	Can be used to fill short term emergency vacancies	9
2	Tray machine operator	Feeds trays into denester	33%	Feeds trays once every 3 minutes. One minute to completely reload the magazines. Can be topped off at any time	1 '	Cannot handle food products without changing gloves	8.2
3	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
4	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
5	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
6	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
7	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
8	Component placer	Adds component to tray	82%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
9	Inspect for missing component	Add to or remove trays with missing components	80%		37'	Cannot change lines without changing uniform	8
10	Line Service	Provides materials to the line in various places	80%	varies constantly during shift	2' to 56'		8.5
11	Line Service	Provides materials to the line in various places	80%	varies constantly during shift	2' to 56'		8.5
12	Film machine operator	Reloads film spindle, splices onto existing roll, removes doubles from splice, rotates spindle, removes spent roll, discards spent roll.	38%	It takes 3 minutes to perform duties every 8 minutes. The actual splicing and changing of the roll takes 45 seconds and the rest of the time is in set up and support fuctions The total of 3 minutes does not have to occur consecutively. Once the splice is made, the rejects created can be dealt with immediately or before the next splice is made. removal of the old roll and reloading the new roll on the spindle works the same way.	45'	Cannot handle food products without changing gloves	8.2
13	Film machine inspector	Looks for loose seals and removes as needed	90%	varies constantly during shift	49'		8
14	Carton machine operator	Reloads flat cartons into machine	20%	30 seconds to reload every 150 seconds. Machine can be topped off at any time. The magazine does not have to be completely empty.	56'	Cannot handle food products without changing gloves	8.4
15	Final inspector	Removes open, unsealed or damged cartons	60%	varies constantly during shift	61'		8.4
16	Wgt control	Continually monitors weights of product, adjusts machine settings as needed, produces control charts for 6 sigma program	75%		varies	Can be used in an emergency but every minute this job is unfilled it costs you money	8.4
17	Quality Control inspector	Checks component weights every 60 minutes, total weights every 20 minutes and verifies day coding information every two hours. Maintains the official USDA complance records for weight	42%		varies	Must be HACCP certified and tasks are required by law
18	Maintnenance person	Monitors the line, makes repairs and adjustments as needed	95%		varies	Do not combine with anything	9
19	Case packer operator	Feeds blank cases into case packer, changes out pallets of blanks	33%	Feeds blanks for 1 minute every 3 minutes	90'	The line produces a maximum of 24 cases per minute	8.2
20	Case stacker	Stacks finished cases onto a CHEP pallet	55%	Stacks one case every 5.5 seconds. Capable of 20 cases per minute	112'	Can backlog cases for ~ 30 seconds without issue	8.4
21	Case stacker	Stacks finished cases onto a CHEP pallet	55%	Stacks one case every 5.5 seconds. Capable of 20 cases per minute	112'	Can backlog cases for ~ 30 seconds without issue	8.4
22	Remove to warehouse	Takes finished pallet to freezer	95%	One pallet every 3 minutes	120' to 275'	Reports to warehouse	8.3
23	Prep employee	Prepares product for line in remote location	80%		225'	Loads the system at the beginning of shift and adjusts for zero run out at shift end	9.5
24	Prep employee	Prepares product for line in remote location	80%		120'	Loads the system at the beginning of shift and adjusts for zero run out at shift end	9
25	Prep employee	Prepares product for line in remote location	80%		90'	Loads the system at the beginning of shift and adjusts for zero run out at shift end	8.5
26	Reject worker	Reworks or dumps product removed from line	75%		50"	Varies by product. Can be used on other lines if demand is there	8

Line (3)

Job #	Job title	Job description	% Utilization	Frequency	Distance from Tray denester (front of line)	Special Notes	Hours worked per day
1	Lead person	Directs employees, gives breaks, orders supplies and any other tasks as needed	100%		varies	Can be used to fill short term emergency vacancies	9
2	Tray machine operator	Feeds trays into denester	33%	Feeds trays once every 3 minutes. One minute to completely reload the magazines. Can be topped off at any time	1 '	Cannot handle food products without changing gloves	8.2
3	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
4	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
5	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
6	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
7	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
8	Component placer	Adds component to tray	82%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
9	Inspect for missing component	Add to or remove trays with missing components	80%		37'	Cannot change lines without changing uniform	8
10	Line Service	Provides materials to the line in various places	80%	varies constantly during shift	2' to 56'		8.5
11	Line Service	Provides materials to the line in various places	80%	varies constantly during shift	2' to 56'		8.5
12	Film machine operator	Reloads film spindle, splices onto existing roll, removes doubles from splice, rotates spindle, removes spent roll, discards spent roll.	38%	It takes 3 minutes to perform duties every 8 minutes. The actual splicing and changing of the roll takes 45 seconds and the rest of the time is in set up and support fuctions The total of 3 minutes does not have to occur consecutively. Once the splice is made, the rejects created can be dealt with immediately or before the next splice is made. removal of the old roll and reloading the new roll on the spindle works the same way.	45'	Cannot handle food products without changing gloves	8.2
13	Film machine inspector	Looks for loose seals and removes as needed	90%	varies constantly during shift	49'		8
14	Carton machine operator	Reloads flat cartons into machine	20%	30 seconds to reload every 150 seconds. Machine can be topped off at any time. The magazine does not have to be completely empty.	56'	Cannot handle food products without changing gloves	8.4
15	Final inspector	Removes open, unsealed or damged cartons	60%	varies constantly during shift	61'		8.4
16	Wgt control	Continually monitors weights of product, adjusts machine settings as needed, produces control charts for 6 sigma program	75%		varies	Can be used in an emergency but every minute this job is unfilled it costs you money	8.4
17	Quality Control inspector	Checks component weights every 60 minutes, total weights every 20 minutes and verifies day coding information every two hours. Maintains the official USDA complance records for weight	42%		varies	Must be HACCP certified and tasks are required by law
18	Maintnenance person	Monitors the line, makes repairs and adjustments as needed	95%		varies	Do not combine with anything	9
19	Case packer operator	Feeds blank cases into case packer, changes out pallets of blanks	33%	Feeds blanks for 1 minute every 3 minutes	90'	The line produces a maximum of 24 cases per minute	8.2
20	Case stacker	Stacks finished cases onto a CHEP pallet	55%	Stacks one case every 5.5 seconds. Capable of 20 cases per minute	112'	Can backlog cases for ~ 30 seconds without issue	8.4
21	Case stacker	Stacks finished cases onto a CHEP pallet	55%	Stacks one case every 5.5 seconds. Capable of 20 cases per minute	112'	Can backlog cases for ~ 30 seconds without issue	8.4
22	Remove to warehouse	Takes finished pallet to freezer	95%	One pallet every 3 minutes	120' to 275'	Reports to warehouse	8.3
23	Prep employee	Prepares product for line in remote location	80%		225'	Loads the system at the beginning of shift and adjusts for zero run out at shift end	9.5
24	Prep employee	Prepares product for line in remote location	80%		120'	Loads the system at the beginning of shift and adjusts for zero run out at shift end	9
25	Prep employee	Prepares product for line in remote location	80%		90'	Loads the system at the beginning of shift and adjusts for zero run out at shift end	8.5
26	Reject worker	Reworks or dumps product removed from line	75%		50"	Varies by product. Can be used on other lines if demand is there	8

Line (4)

Job #	Job title	Job description	% Utilization	Frequency	Distance from Tray denester (front of line)	Special Notes	Hours worked per day
1	Lead person	Directs employees, gives breaks, orders supplies and any other tasks as needed	100%		varies	Can be used to fill short term emergency vacancies	9
2	Tray machine operator	Feeds trays into denester	33%	Feeds trays once every 3 minutes. One minute to completely reload the magazines. Can be topped off at any time	1 '	Cannot handle food products without changing gloves	8.2
3	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
4	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
5	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
6	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
7	Component placer	Adds component to tray	84%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
8	Component placer	Adds component to tray	82%	Places a component every 1.25 seconds	12'	Cannot change lines without changing uniform	8
9	Inspect for missing component	Add to or remove trays with missing components	80%		37'	Cannot change lines without changing uniform	8
10	Line Service	Provides materials to the line in various places	80%	varies constantly during shift	2' to 56'		8.5
11	Line Service	Provides materials to the line in various places	80%	varies constantly during shift	2' to 56'		8.5
12	Film machine operator	Reloads film spindle, splices onto existing roll, removes doubles from splice, rotates spindle, removes spent roll, discards spent roll.	38%	It takes 3 minutes to perform duties every 8 minutes. The actual splicing and changing of the roll takes 45 seconds and the rest of the time is in set up and support fuctions The total of 3 minutes does not have to occur consecutively. Once the splice is made, the rejects created can be dealt with immediately or before the next splice is made. removal of the old roll and reloading the new roll on the spindle works the same way.	45'	Cannot handle food products without changing gloves	8.2
13	Film machine inspector	Looks for loose seals and removes as needed	90%	varies constantly during shift	49'		8
14	Carton machine operator	Reloads flat cartons into machine	20%	30 seconds to reload every 150 seconds. Machine can be topped off at any time. The magazine does not have to be completely empty.	56'	Cannot handle food products without changing gloves	8.4
15	Final inspector	Removes open, unsealed or damged cartons	60%	varies constantly during shift	61'		8.4
16	Wgt control	Continually monitors weights of product, adjusts machine settings as needed, produces control charts for 6 sigma program	75%		varies	Can be used in an emergency but every minute this job is unfilled it costs you money	8.4
17	Quality Control inspector	Checks component weights every 60 minutes, total weights every 20 minutes and verifies day coding information every two hours. Maintains the official USDA complance records for weight	42%		varies	Must be HACCP certified and tasks are required by law	8
18	Maintnenance person	Monitors the line, makes repairs and adjustments as needed	95%		varies	Do not combine with anything	9
19	Case packer operator	Feeds blank cases into case packer, changes out pallets of blanks	33%	Feeds blanks for 1 minute every 3 minutes	90'	The line produces a maximum of 24 cases per minute	8.2
20	Case stacker	Stacks finished cases onto a CHEP pallet	55%	Stacks one case every 5.5 seconds. Capable of 20 cases per minute	112'	Can backlog cases for ~ 30 seconds without issue	8.4
21	Case stacker	Stacks finished cases onto a CHEP pallet	55%	Stacks one case every 5.5 seconds. Capable of 20 cases per minute	112'	Can backlog cases for ~ 30 seconds without issue	8.4
22	Remove to warehouse	Takes finished pallet to freezer	95%	One pallet every 3 minutes	120' to 275'	Reports to warehouse	8.3
23	Prep employee	Prepares product for line in remote location	80%		225'	Loads the system at the beginning of shift and adjusts for zero run out at shift end	9.5
24	Prep employee	Prepares product for line in remote location	80%		120'	Loads the system at the beginning of shift and adjusts for zero run out at shift end	9
25	Prep employee	Prepares product for line in remote location	80%		90'	Loads the system at the beginning of shift and adjusts for zero run out at shift end	8.5
26	Reject worker	Reworks or dumps product removed from line	75%		50"	Varies by product. Can be used on other lines if demand is there	8

Answer

Answers and calculations

Describe your combinations/elimination below. If you wish to use excel and show your work use the first three rows and columns b to g as needed. If you wish to use a separate Word or Excel document to attached to dropbox you may do so.