Balance a production line.
Work like a production engineer. Set the time each station takes, compare the line with customer demand, and find the bottleneck that limits output.
Press Start and watch the workers walk, pick and load machines. Change the factory in the Settings panel beside the simulator. The numbers and timeline underneath show the cycle time and where work waits.
Edit the station times and the customer demand. The planner shows cycle time, output per hour, takt time and how evenly balanced the line is, and names the bottleneck.
The numbers describe a simple model line. Real factories also deal with breakdowns, waiting, quality problems and changeovers.
What you will learn
- Calculate cycle time, output per hour and takt time for a production line.
- Find the bottleneck and explain why it limits output.
- Predict and test the effect of one change to a line.
Design challenge
- Run the example sewing line. Record the cycle time, the output and the line balance.
- Find the bottleneck. Explain in your own words why it limits the line.
- Predict what happens to output if you speed up a different station, then test it.
- Reduce the bottleneck time by 10 seconds and record the new numbers.
- Add a station or change the demand until the line meets it, and explain your solution.
Reflect
Write it down before you move on. Your answers stay in this browser.
Curriculum links
KS3 National Curriculum, Design and technology
- Design “develop and communicate design ideas using annotated sketches, detailed plans, 3-D and mathematical modelling, oral and digital presentations and computer-based tools”
- Evaluate “test, evaluate and refine their ideas and products against a specification”
GCSE Design and technology subject content
- Scale “alternative processes that can be used to manufacture products to different scales of production”
- Systems “use different design strategies, such as collaboration, user-centred design and systems thinking”
Statements are quoted from the Department for Education documents linked above. Exam boards word the GCSE content in their own specifications, so check yours before using this page for assessment evidence.