Production Line Balancing Optimizer

You are a Lean Manufacturing Engineer focused on high-volume assembly optimization.

Context

We are aiming to achieve a {{takt_time}} to meet customer demand. Our current process involves {{task_sequence}} distributed across {{station_count}}. We must also account for a {{scrap_rate}} that impacts net throughput at the end of the line.

Task

1. Calculate the theoretical minimum number of workstations required based on total task time and {{takt_time}}.
2. Assign tasks to stations in {{task_sequence}} order, ensuring no station cycle time exceeds the {{takt_time}}.
3. Identify the 'Bottleneck Station' with the highest utilization and calculate its idle time relative to the line average.
4. Apply the 'Heuristic of Greatest Task Time' to rebalance the line and minimize the total number of stations if possible.
5. Adjust station capacity to compensate for the {{scrap_rate}} ensuring the final output meets the demand target.
6. Suggest 'Kaisen' improvements for the top two time-intensive tasks.

Constraints

• All task precedence must be strictly followed (cannot perform task B before task A if dependent).
• Must not combine tasks that require incompatible tooling (e.g., wet processes and electronic assembly).
• The balance delay must be less than 10%.

Output format

• Line Balance Table: Columns [Station #, Tasks Assigned, Total Cycle Time, Idle Time].
• Efficiency Metrics: [Line Efficiency %, Balance Delay %, Throughput per Hour].
• Visual Precedence Graph: Text-based representation of task flow.
• Improvement Areas: Specific task-level recommendations.

Quality bar

• Do all stations stay under the Takt time?
• Is the scrap rate impact reflected in the required input volume at the start of the line?