Kinga Doll Company manufactures eight versions of its popular girl doll, Shari. The company operates on a 40-hour workweek. The eight versions differ in doll skin, hair, and eye color, enabling most children to have a doll with a similar appearance to them. It currently sells an average of 4,000 dolls (spread equally among its eight versions) per week to boutique toy retailers. In simplified terms, doll making at Kinga involves three basic operations: molding the body and hair, painting the face, and dressing the doll. Changing over between versions requires setup time at the molding and painting stations due to the different colors of plastic pellets, hair, and eye color paint required. Table 7.5 lists the setup times for a batch and the activity times for each unit at each step. process setup molding painting dressing setup time (min) 12 29.00 no setup processing time (min) .24 0.17 0.27 a. What is the process capacity in dolls per hour with a batch size of 475 dolls? b. What is the utilization of molding in dolls per hour with a batch size of 900 dolls? c. Which batch size would minimize inventory without decreasing the process capacity? d. Which batch size would minimize inventory without decreasing the current flow rate?
Kinga Doll Company manufactures eight versions of its popular girl doll, Shari. The company operates on a 40-hour workweek. The eight versions differ in doll skin, hair, and eye color, enabling most children to have a doll with a similar appearance to them. It currently sells an average of 4,000 dolls (spread equally among its eight versions) per week to boutique toy retailers. In simplified terms, doll making at Kinga involves three basic operations: molding the body and hair, painting the face, and dressing the doll. Changing over between versions requires setup time at the molding and painting stations due to the different colors of plastic pellets, hair, and eye color paint required. Table 7.5 lists the setup times for a batch and the activity times for each unit at each step.
| process setup | molding | painting | dressing |
| setup time (min) | 12 | 29.00 | no setup |
| processing time (min) | .24 | 0.17 | 0.27 |
a. What is the process capacity in dolls per hour with a batch size of 475 dolls?
b. What is the utilization of molding in dolls per hour with a batch size of 900 dolls?
c. Which batch size would minimize inventory without decreasing the process capacity?
d. Which batch size would minimize inventory without decreasing the current flow rate?
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