Operations Management
17th Edition
ISBN: 9781259142208
Author: CACHON, Gérard, Terwiesch, Christian
Publisher: Mcgraw-hill Education,
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Question
Chapter 5, Problem 5PA
a)
Summary Introduction
To identify: The bottleneck step in the process.
b)
Summary Introduction
To determine: The capacity of the process.
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. Consider the following four-step assembly operation with quality problems. Allresources are staffed by one employee.• The first resource has a processing time of 5 minutes per unit.• The second resource has a processing time of 6 minutes per unit.• The third resource has a processing time of 3 minutes per unit. With a 30 percent probability, the flow unit coming out of the third resource has to be reworked. In that case,the operations at the first, second, and third resources are repeated. You can assumethat (a) rework always succeeds (i.e., a unit going through the rework loop will alwayswork after the third resource) and (b) the processing times for units in rework are thesame as for regular units.• The fourth resource has a processing time of 4 minutes per unit.a. Where in the process is the bottleneck?b. What is the capacity of the process?
Consider the following three-step assembly operation with quality problems. All resources 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% probability, the flow unit coming out of the third resource has to be reworked. In that case, the operations at the second and third resources are repeated. You can assume that (a) rework always succeeds (i.e. a unit going through the rework loop will always work after the third resource),and (b) the processing times for units in rework are the same as for regular units.
Where in the process is the bottleneck?
1 point
Step 3
Step 2
Step 1
5.Question 5
Consider the following three-step assembly operation with quality problems. All resources 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% probability, the flow unit coming out of the third resource has to be reworked. In that case, the operations at the second and third resources are repeated. You can assume that (a) rework always succeeds (i.e. a unit going through the rework loop will always work after the third resource),and (b) the processing times for units in rework are the same as for regular units.
For every unit of demand, how many units have to flow through the second step in the process?
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- Consider the following three-step assembly operation with quality problems. All resources 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% probability, the flow unit coming out of the third resource has to be reworked. In that case, the operations at the second and third resources are repeated. You can assume that (a) rework always succeeds (i.e. a unit going through the rework loop will always work after the third resource),and (b) the processing times for units in rework are the same as for regular units. Where in the process is the bottleneck?arrow_forward3-Step Process with Rework Consider the following three-step assembly operation with quality problems. All resources 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% probability, the flow unit coming out of the third resource has to be reworked. In that case, the operations at the second and third resources are repeated. You can assume that (a) rework always succeeds (i.e. a unit going through the rework loop will always work after the third resource),and (b) the processing times for units in rework are the same as for regular units. A) For every unit of demand, how many units have to flow through the second step in the process? B) Where in the process is the bottleneck? Step 1, 2 or 3?arrow_forwardConsider the following four-step assembly operation with quality problems: The first resource has a processing time of 5 minutes per unit and one employee doing the operation. The second resource has a processing time of 4 minutes per unit. It also has one employee doing the operation. However, this is a very delicate task and 80% of all products have to be scrapped after this step. Two workers are staffed for the third resource. No quality problems occur at this resource and the processing time is 20 minutes per unit. At the fourth and final resource, one operator handles the product. No quality problems exist at this step and the processing time is 12 minutes per unit. For every unit of demand, how many units have to flow through the second step in the process?arrow_forward
- Consider the following four-step assembly operation with quality problems: The first resource has a processing time of 5 minutes per unit and one employee doing the operation. The second resource has a processing time of 4 minutes per unit. It also has one employee doing the operation. However, this is a very delicate task and 80% of all products have to be scrapped after this step. Two workers are staffed for the third resource. No quality problems occur at this resource and the processing time is 20 minutes per unit. At the fourth and final resource, one operator handles the product. No quality problems exist at this step and the processing time is 12 minutes per unit. Where in the process is the bottleneck?arrow_forwardA small, privately owned Asian company is producing a private-label soft drink called Yoggo. A bottling line puts the soft drinks into plastic bottles and then packages the bottles into boxes holding 10 bottles each. The bottling line is comprised of the following four steps: (1) the bottling machine takes 1 second to fill a bottle, (2) the lid machine takes 3 seconds to cover the bottle with a lid, (3) a labeling machine takes 3 seconds per bottle, and (4) the packaging machine takes 4 seconds to place a bottle into a box. When a box has been filled with 10 bottles, a worker tending the packaging machine removes the filled box and replaces it with an empty box. Assume that the time for the worker to remove a filled box and replace it with an empty box is negligible and hence does not affect the capacity of the line. Problem data are summarized in the following table. Process Step Number of Machines Seconds per Bottle Bottling 1 1 Apply a lid 1 3 Labeling 1 3 Packaging 1 4…arrow_forwardA small, privately owned Asian company is producing a private-label soft drink called Yoggo. A bottling line puts the soft drinks into plastic bottles and then packages the bottles into boxes holding 10 bottles each. The bottling line is comprised of the following four steps: (1) the bottling machine takes 1 second to fill a bottle, (2) the lid machine takes 3 seconds to cover the bottle with a lid, (3) a labeling machine takes 3 seconds per bottle, and (4) the packaging machine takes 4 seconds to place a bottle into a box. When a box has been filled with 10 bottles, a worker tending the packaging machine removes the filled box and replaces it with an empty box. Assume that the time for the worker to remove a filled box and replace it with an empty box is negligible and hence does not affect the capacity of the line. Problem data are summarized in the following table. Assuming unlimited demand, what would be the flow rate? Assuming unlimited demand, what would be the utilization at…arrow_forward
- A copy machine is available 24 hours a day. On a typical day, the machine produces 100 jobs. Each job takes about 3 minutes on the machine, 2 minutes of which is processing time and 1 minute is setup time (logging in, defining the job). About 20 Percent of the jobs need to be reworked, in which case the setup time and the processing time have to be repeated. The remainder of the time, the equipment is idle. What is the OEE of the equipment? answer:______percentarrow_forward. A small, privately owned Asian company is producing a private-label soft drink calledYoggo. A bottling line puts the soft drinks into plastic bottles and then packagesthe bottles into boxes holding 10 bottles each. The bottling line is comprised of thefollowing four steps: (1) the bottling machine takes 1 second to fill a bottle, (2) the lidmachine takes 3 seconds to cover the bottle with a lid, (3) a labeling machine takes3 seconds per bottle, and (4) the packaging machine takes 4 seconds to place a bottleinto a box. When a box has been filled with 10 bottles, a worker tending the packagingmachine removes the filled box and replaces it with an empty box. Assume that thetime for the worker to remove a filled box and replace it with an empty box is negligibleand hence does not affect the capacity of the line. Problem data are summarized in thefollowing table. a. Draw a process flow diagram of this process. b. What is the capacity (bottles/hour) at the resource “Apply a lid”? c. What…arrow_forwardWhat 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 defectarrow_forward
- This is a step in a process that is the slowest compared tothe other steps. This step limits the capacity of the process.arrow_forwardBefore 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.arrow_forwardSuppose you have a process that requires 20 minutes for start up, 13 minutes for Task #1, 15 minutes for Task #2, and 18 minutes for Task #3. Which of the following is true? Group of answer choices This process has one or more tasks that are blocking other tasks. None of these answers is correct This process has one or more tasks that are starving other tasks. This process has one or more tasks that are multi-staging other tasks. This process has one or more tasks that are buffering other tasks.arrow_forward
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