18Every company has a Bottleneck True False 19Capacity of each sequence in a process is independent of bottleneck True False 20 Design Capacity can be modified True False Expert Answer
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- Consider a two-step process that handles three types of customers. Each resourceis staffed by one employee. Type 1 customers spend 5 minutes at resource 1 and 2 minutesat resource 2. Type 2 customers also spend 5 minutes at resource 1, but spend 10 minutes atresource 2. Finally, type 3 customers spend no time at resource 1 and 8 minutes at resource2. Each hour, the demand is 10 customers of type 1, 4 customers of type 2, and 2 customers oftype 3. Where in the process is the bottleneck? What is the flow rate for each customer type?Raquel’s Landscaping Company has contracted for several landscaping jobs. Each job requires preparing the areas (identifying the locations and types of plants, preparing the soil, etc.) and then planting the trees, bushes, and shrubs. The expected time for each of the jobs is shown next. Job Preparingthe Area (days) Planting(days) R 3 2 S 1 3 T 4 5 U 8 5 V 6 4 W 4 3 Raquel is concerned with efficiency. She believes it is probably more efficient to use SPT (shortest processing time) as her priority rule. (a) Develop a sequence using SPT based on processing time for preparing the area. (If two of more jobs have the same processing time, list them alphabetically.) Preparing the Area select a job select a job select a job…A process improvement team is working to improve the production output at the Johnson Manufacturing plant’sHeader Cell that manufactures a key component, headers, used in commercial air conditioners. A header is partof the circulatory system of a commercial air conditioner that moves coolant between various components suchas the evaporator coil and the condenser coil. Currently, the header production cell is scheduled separately fromthe main work in the plant. Often, individual headers are not sequenced to match the product they go into on thefinal assembly line in a timely fashion, and so the product can sit in queue waiting for a header
- An independent accountant is planning to prepare tax returns for six of her clients.Prior to her actually preparing each return, her secretary checks the client’s file to besure all the necessary documentation is there and obtains all the tax forms needed forthe preparation of the return. Based on past experience with the clients, her secretaryestimates that the following times (in hours) are required for preparation of the returnand for the accountant to complete the necessary paperwork prior to filing each return:Client Secretary Time Accountant Time1 1.2 2.52 1.6 4.53 2.0 2.04 1.5 6.05 3.1 5.06 0.5 1.5In what order should the work be completed in order to minimize the total timerequired for all six clients?A furniture factory makes two types of wooden tables,large and small. See the flowchart below .Small tables are made in batches of 100, and large tables are made in batches of 50. A batch includes a fixed setup time for the entire batch at each process step and a run time for each piece in the batch. Both large and small tables have the same processing times. The capacities of each process step are given, and apply to production of either type of table, as shown in the flowchart. a. What is the capacity of the system, and what is thebottleneck? b. What are the throughput times for batches of large and small tables? c. When producing at a rate of six small tables per hour on average, how many tables will be in the system?EU Company manufactures two different types of life vests (A and B) that are manufactured and assembled on three different workstations (W, X, and Y) using a small-batch process (see Figure 1). Batch setup times are negligible. The flowchart denotes the path each product follows through the manufacturing process, and each product’s price, demand per week, and processing times per unit are indicated as well. Purchased parts and raw materials consumed during production are represented by inverted triangles. EU can make and sell up to the limit of its demand per week; no penalties are incurred for not being able to meet all the demand. Each workstation is staffed by a worker who is dedicated to work on that workstation alone and is paid $6 per hour for an entire week, regardless of how much the worker is used. Total labor costs per week are fixed. Variable overhead costs are $1,500/week. The plant operates one 8-hour shift per day, or 40 hours/week. Which of the three workstations, W,…
- The Hickory Company manufactures wooden desks. Manage-ment schedules overtime every weekend to reduce the backlogon the most popular models. The automatic routing machineis used to cut certain types of edges on the desktops. The fol-lowing orders need to be scheduled for the routing machine: The due dates reflect the need for the order to be at its nextoperation.a. Develop separate schedules by using the FCFS and EDDrules. Compare the schedules on the basis of average flowtime and average past due hours.b. Comment on the performance of the two rules relative tothese measuresConsider the following batch-flow process consisting of three process stepsperformed by three machines. Process steps step 1 step 2 step 3 processing time 0.25min./unit 0.20 min./unit 0.15 min./unit setup time 30 min 20 min 45 min Work is processed in batches at each step. Before a batch is processed at a step, the machine atthat step must be set up. (During a setup, the machine is unable to process any product.) Assumethat there is a dedicated setup operator for each machine (i.e., there is always someone availableto perform a setup at each machine.)a. What is the capacity of step 1 if the batch size is 35 parts?b. For what batch sizes is step 1 (2, 3) the bottleneck?Consider the following production process for manufacturing biscuits. The first step ofthe process is mixing, where all of the ingredients are combined in the correct proportion to form dough. In the next step of the process, the dough is formed into sheets andcut into pieces in preparation for baking. The cut dough is then baked into biscuits andsubsequently must be cooled. The final step of the process is packaging the biscuits forthe consumer.The following table summarizes the production process along with the processing timesat each step of the process. The process is highly automated, so assume that this is amachine-paced process with one machine available at each step.a. What is the capacity of the baking process step (in batches per hour)? b. What is the bottleneck of the manufacturing process? c. Assuming unlimited demand, what is the process flow rate (in batches per hour)? d. Assuming unlimited demand, what is the utilization of the mixing process step? e. If the…
- A company makes four products that have the following characteristics:Product A sells for $75 but needs $40 of materials to produce; Product B sells for $90 but needs $65 ofmaterials to produce; Product C sells for $110 but needs $80 of materials to produce; Product D sells for$135 but needs $105 of materials to produce. The processing requirements for each product on each ofthe four machines are shown in the table. Work centers W, X, Y, and Z are available for 5 days per week, 1 shift per day (8 hrs.) and have no setuptime when switching between products. Market demand is 50 As, 60 Bs, 70 Cs, and 80 Ds per week. In thequestions that follow, the traditional method refers to maximizing the contribution margin per unit foreach product, and the bottleneck method refers to maximizing the contribution margin per minute at thebottleneck for each product. Each worker is paid $15 per hour and is paid for an entire week, regardlessof how much the worker is used. Using the bottleneck method,…A company makes four products that have the following characteristics:Product A sells for $75 but needs $40 of materials to produce; Product B sells for $90 but needs $65 ofmaterials to produce; Product C sells for $110 but needs $80 of materials to produce; Product D sells for$135 but needs $105 of materials to produce. The processing requirements for each product on each ofthe four machines are shown in the table. Work centers W, X, Y, and Z are available for 5 days per week, 1 shift per day (8 hrs.) and have no setuptime when switching between products. Market demand is 50 As, 60 Bs, 70 Cs, and 80 Ds per week. In thequestions that follow, the traditional method refers to maximizing the contribution margin per unit foreach product, and the bottleneck method refers to maximizing the contribution margin per minute at thebottleneck for each product. Each worker is paid $15 per hour and is paid for an entire week, regardlessof how much the worker is used. Using the traditional…A company makes four products that have the following characteristics:Product A sells for $75 but needs $40 of materials to produce; Product B sells for $90 but needs $65 ofmaterials to produce; Product C sells for $110 but needs $80 of materials to produce; Product D sells for$135 but needs $105 of materials to produce. The processing requirements for each product on each ofthe four machines are shown in the table. Work centers W, X, Y, and Z are available for 5 days per week, 1 shift per day (8 hrs.) and have no setuptime when switching between products. Market demand is 50 As, 60 Bs, 70 Cs, and 80 Ds per week. In thequestions that follow, the traditional method refers to maximizing the contribution margin per unit foreach product, and the bottleneck method refers to maximizing the contribution margin per minute at thebottleneck for each product. Each worker is paid $15 per hour and is paid for an entire week, regardlessof how much the worker is used. Using the bottleneck method,…