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- Balancing a process with a fixed sequence of activities will achieve a higher average labor utilization than balancing a process with no fixed sequence of activities. True or False?onsider a process consisting of three resources. Assume there exists unlimited demand for the product, and that all activities are always performed in the following sequence. Resource 1 has a processing time of 6 minutes per unit. Resource 2 has a processing time of 3 minutes per unit. Resource 3 has a processing time of 5 minutes per unit. All three resources are staffed by one worker and each worker gets paid $14 per hour. How much idle time does the worker at resource 3 have per unit?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
- Consider a balanced line consisting of five single-machine stations with exponential process times. Suppose the utilization is 75 percent and the line runs under the CONWlP protocol (i.e., a new job is started each time a job is completed). a. What is the WlP level in the line? b. What is the cycle time as a percentage of To? c. What happens to WIP, CT, and TH relative to the original system if you make each of the following changes (one at a time)? i. Increase the WIP level ii. Decrease the variability of one station iii. Decrease the capacity at one station iv. Increase the capacity of all stationsConsider the following two-step process. Step 1 takes 10 minutes per unit and hasan 80 percent yield. Step 2 takes 15 minutes per unit and has a 60 percent yield. Where inthe process is the bottleneck? How many good units can the process produce?. 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?
- . Consider a four-step serial process with processing times given in the following list.There is one machine at each step of the process, and this is a machine-paced process.• Step 1: 25 minutes per unit• Step 2: 15 minutes per unit• Step 3: 30 minutes per unit• Step 4: 20 minutes per unitAssuming that the process starts out empty, how long will it take (in hours) to completea batch of 105 units?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.For a given process, the raw processing time is 102 sec, the bottleneck cycle time is 20 sec/item, and the WIP is 6 items. The critical WIP value is ____ items. Round answer to one decimal place.
- Maximum cycle time is the sum of all task times when the tasks are running in parallel . Select one: a . FALSE b. TRUEBecause of long setup times, a company chooses to run big production batches. Whichof the following actions will level the production schedule?a. Using overtimeb. Mixing the models on the final linec. Making sure that rework is kept lowd. Reducing the waste of the processFormtech Inc. produces transformers. Each order is custom designed and manufactured for the customer. Each order goes through 3 phases: Transformer Design, which takes 4 weeks. Procurement, which has a lead time of 8 weeks. Assembly and Testing, which takes 4 weeks The design group can handle only 4 projects at any given time. The other groups are not capacity constrained. How much total work-in-process (number of projects started but not yet completed) does the company typically have? (Hint: Little's Law)