For a batch size of 40 parts, what is the capacity of stage 1 in (parts per minute)? 0.57
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- Consider 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 two production processes making an electronic component for a navigation system. Both processes consist of 20 stations and operate at a cycletime of 1 minute/unit. Their most error-prone operation is step 9:• Process 1 has a final inspection at the end of the process and has about 300 units of inventory between step 9 and the inspection.• Process 2 has each worker check the work of the previous steps and about 50 units ofinventory between step 9 and the end of the process, roughly equally distributed across theremainder of the process.What would be the information turnaround time for a defect made at station 9?H4. A manufacturing process consists of three processes. Step 1 requires 4 minutes per unit, step 2 requires 6 minutes per unit, and step 3 requires 7 minutes per unit. 20% of units that complete the third step require rework, which means those units must start the process over at step 2 (processing times are the same for units being reworked) and rework is always successful. Demand at the shop is 0.4 units per minute. What is the capacity of the shop (in units per minute)?
- What is the relationship between a process with rework and a process with scrap?a. Scrap and rework are not related.b. Scrap and rework are sequential processes. First, items are scrapped and then they arereworked.c. A process either has scrap or rework. The two are mutually exclusive. d. Scrap is a special case of rework in which flow units have to repeat all resources in the process up to the defectA catalog order-filling process can be described as follows:12 Telephone orders are taken over a 12-hour period each day. Orders are collected from each person at the end of the day and checked for errors by the supervisor of the phone department, usually the following morning. The supervisor does not send each one-day batch of orders to the data processing department until after 1:00 p.m. In the next step—data processing—orders are invoiced in the one-day batches. Then they are printed and matched back to the original orders. At this point, if the order is from a new customer, it is sent to the person who did the customer verification and setup of new customer accounts. This process must be completed before the order can be invoiced. The next step—order verification and proofreading—occurs after invoicing is completed. The orders, with invoices attached, are given to a person who verifies that all required information is present and correct to permit typesetting. If the verifier has…Consider a production line with five stations in serial. The stations have the following process times in minutes (or minutes/unit). Station 1's process time is 9 minutes/unit. Station 2's process time is 10 minutes/unit. Station three has two identical machines, each of which process a unit in 12 minutes (each unit only needs to be processed on one of the two machines). Station 4's process time is 5 minutes/unit. Station 5's process time is 8 minutes/unit. Which station is the bottleneck station? a) Station 3 b) None of the other options c) Station 2 d) Station 5
- Before completing production, a product must passthrough three stages of production. On the average, a newproduct begins at stage 1 every 6 minutes. The average timeit takes to process the product at each stage is as follows:stage 1, 3 minutes; stage 2, 2 minutes; stage 3, 1 minute.After finishing at stage 3, the product is inspected (assumethis takes no time). Ten percent of the final products arefound to have a defective part and must return to stage 1 andgo through the entire system again. After completing stage3, 20% of the final products are found to be defective. Theymust return to stage 2 and pass through 2 and 3 again. Onthe average, how many jobs are in the system? Assume thatall interarrival times and service times are exponential andthat each stage consists of a single server.. Consider the following three-step assembly operation with quality problems. Allresources are staffed by one employee.• The first resource has a processing time of 7 minutes per unit.• The second resource has a processing time of 6 minutes per unit.• The third resource has a processing time of 5 minutes per unit. With a 40 percentprobability, the flow unit coming out of the third resource has to be reworked. In thatcase, the operations at the second and third resources are repeated. You can assumethat (a) rework always succeeds (i.e., a unit going through the rework loop willalways work after the third resource) and (b) the processing times for units in reworkare the same as for regular units.Where in the process is the bottleneck? What is the capacity of the process?Suppose a resource has setup times and a setup time must be incurred each time theresource switches production to a different product. Requiring the resource to make anew product (that requires its own setup) is likely to have what effect on the process?a. Inventory for existing products remains the same, but the process must now carryinventory of the new product.b. Inventory of all products is likely to increase.c. Inventory of existing products decreases even though the process must now carryinventory of the new product.d. Inventory of products with short setup times will decrease, while inventory of products with long setup times will increase.
- This is a step in a process that is the slowest compared tothe other steps. This step limits the capacity of the process.Consider the following batch flow process consisting of three process steps performed by three machines. What is the capacity of the process given the following information? Batch size = 50 parts Step 1 - Processing Time = 1 minute/part; Setup time = 20 minutes Step 2 - Processing Time = 2 minute/part; Setup time = no setup Step 3 - Processing Time = 1.5 minute/part; Setup time = no setup. Aquatica makes underwater camera housings for divers. The process begins with a solid rectangular block of aluminum that is used to make a single housing. A computer numerically controlled (CNC) machine drills into the block to make the metal “frame” of the housing. Each block requires 15 minutes of drilling. The frame is then chemically treated in a series of baths. There is ample capacity in the treating stage. Finally, a worker must manually attach the various buttons and components to the metal housing. This assembly takes 120 minutes per housing per worker and Aquatica has 6 workers trained to do this task. The CNC machine requires a 30-minute setup time before the production of a batch can begin. a. If the CNC machine produces 14 housings between setups, what would be its capacity (in housings per hour)? b. Assuming the process is supply-constrained, what is the utilization (as a number between 0 and 1) of the CNC machine if it operates in batches of 14 housings? c. Assuming…