A worked line-balancing case study for a real countertop-blender assembly line — takt time from demand, task-time and precedence data, a largest-candidate-rule station assignment, and a before/after comparison of cycle time, station count, and line efficiency.
The project brief: a small-appliance manufacturer's manual blender-assembly line was built up piecemeal over several product model years, with tasks assigned to workstations by supervisor tribal knowledge rather than a formal precedence diagram. A time study finds the line's real bottleneck cycle time running well above the takt time its own sales demand requires — and this module rebalances the line's ten work elements across the fewest workstations that can sustain that takt time.
This module walks the whole analysis the way a real industrial engineer would: a worked takt-time calculation from monthly demand, the full ten-task time-and-precedence dataset, a step-by-step largest-candidate-rule station assignment, and a before/after comparison of cycle time, station count, line efficiency, and shift output capacity. The full worked numbers, before/after metrics table, and finished design reasoning are part of the unlocked module below.