MINISTRY OF EDUCATION AND CULTURE

UNIVERSITAS JENDERAL SOEDIRMAN

FACULTY OF ECONOMICS AND BUSINESS
Address: Grendeng Campus, Jln. Prof HR. Boenjamin 708, Purwokerto 53122.  (0281) 637970;
Fax.: (0281)640268; eMail: [email protected]; Website: http://feb.unsoed.ac.id

Note: Answer of the following problem. Submit your answer to me no later than Wednesday, January
8, 2020 at 11:10 a.m in handwritten format.

Problem 14.3
The demand for subassembly S is 100 units in week 7. Each unit of S requires 1 unit of T and
2 units of U. Each unit of T requires 1 unit of V, 2 units of W, and 1 unit of X. Finally, each
unit of U requires 2 units of Y and 3 units of Z. One firm manufactures all items. It takes 2
weeks to make S, 1 week to make T, 2 weeks to make U, 2 weeks to make V, 3 weeks to make
W,1 week to make X, 2 weeks to make Y, and 1 week to make Z.
a) Construct a product structure. Identify all levels, parents, and components.
b) Prepare a time-phased product structure.

Problem 14.4
Using the information in Problem 14.3, construct a gross material requirements plan.

Problem 14.5
Using the information in Problem 14.3, construct a net material requirements plan using the
following on-hand inventory.

On-Hand On-Hand
Item Item
Inventory Inventory
S 20 W 30
T 20 X 25
U 40 Y 240
V 30 Z 40

Problem 14.6
Refer again to Problems 14.3 and 14.4. In addition to 100 units of S, there is also a demand for
20 units of U, which is a component of S. The 20 units of U are needed for maintenance pur-
poses. These units are needed in week 6. Modify the gross material requirements plan to reflect
this change.

Problem 14.7
Refer again to Problems 14.3 and 14.5. In addition to 100 units of S, there is also a demand for
20 units of U, which is a component of S. The 20 units of U are needed for maintenance pur-
poses. These units are needed in week 6. Modify the net material requirements plan to reflect
this change.

Problem 15.4
Molly Riggs's medical testing company wishes to assign a set of jobs to a set of machines. The
following table provides the production cost data of each machine when performing the
specific job:

1
 Machine
Job A B C D
1 8 6 7 5
2 5 6 8 9
3 4 10 6 9
4 6 4 10 7

a. Determine the assignment of jobs to machines that will minimize total production cost,
b. What is the total production cost of your assignments?

Problem 15.13
The following jobs are waiting to be processed at Rick Carlson's machine center. Carlson's
machine center has a relatively long backlog and sets fresh schedules every 2 weeks, which
does not disturb earlier schedules. Below are the jobs received during the previous 2 weeks.
They are ready to be scheduled today, which is day 241 (day 241 is a work day). Job names
refer to names of clients and contract numbers.

Date Job Production Days Date Job

Job
Received Needed Due
BR-02 228 15 300
CX-01 225 25 270
DE-06 230 35 320
RG-05 235 40 360
SY-11 231 30 310
a) Complete the table below. (Show your supporting calculations.)
b) Which dispatching rule has the best score for flow time?
c) Which dispatching rule has the best score for utilization metric?
d) Which dispatching rule has the best score for lateness?
e) Which dispatching rule, would you select? Support your decision.

Utilization Average
Dispatching Job Average
Flow Time Metric Number of
Rule Sequence Lateness
Jobs
EDD
SPT
LPT
FCFS

Problem 16.1
Leblanc Electronics, Inc., in Nashville, produces short runs of custom airwave scanners for the
defense industry. You have been asked by the owner, Larry Leblanc, to reduce inventory by
introducing a kanban system. After several hours of analysis, you develop the following data
for scanner connectors used in one work cell. Flow many kanbans do you need for this
connector?

Daily demand 1,000 connectors

Lead time 2 days
Safety stock 2 day
Kanban size 500 connectors

2
Problem 16.8
Bill Penny has a repetitive manufacturing plant pro- ducing trailer hitches in Arlington, Texas.
The plant has an average inventory turnover of only 12 times per year. He has therefore
determine that he will reduce his component lot sizes. He has developed the following data for
one component, the safety chain clip:

Annual demand = 31,200 units

Daily demand = 120 units
Daily production (in 8 hours) = 960 units
Desired lot size (1 hour of production) = 120 units
Holding cost per unit per year = $12
Setup labor cost per hour = $20

How many minutes of setup time should he have his plant manager aim for regarding this
component?

Problem 16.9
Given the following information about a product, at Phyllis Simon's firm, what is the
appropriate setup time?
Annual demand = 39,000 units
Daily demand = 150 units
Daily production = 1,000 units
Desired lot size = 150 units
Holding cost per unit per year = $10
Setup labor cost per hour = $40

Problem 17.7
A manufacturer of disk drives for notebook computers wants a MTBF of at least 50,000 hours.
Recent test results for 10 units were one failure at 10,000 hrs, another at 25,000 hrs, and two
more at 45,000 hrs. The remaining units were still running at 60,000 hours. Determine the
following:
a) Percent of failures.
b) Number of failures per unit-hour
c) MTBF at this point in the testing

Problem 17.10 Merrill Kim Sharp has a system composed of three cornpatients in parallel.
The components have the following reliabilities:

R1 = 0.90, R2 = 0.95, R3 = 0.85

What is the reliability of the system?

Problem 17.11
A medical control system has three components in series with individual reliabilities (R1, R2,
R3) as shown:
R1 R2 R3
.99 .98 .90 Rs

What is the reliability of the system?

3
Problem 17.16
Rick Wing, salesperson for Wave Soldering Systems, Inc. (WSSI), has provided you with a
proposal for improving the temperature control on your present machine. The machine uses a
hot-air knife to cleanly remove excess solder from printed circuit boards; this is a great
concept, but the hot-air temperature control lacks reliability. According to Wing, engineers at
WSSI have improved the reliability of the critical temperature controls. The new system still
has the four sensitive integrated circuits controlling the temperature, but the new machine has
a backup for each. The four integrated circuits have reliabilities of .90, .92, .94, and .96. The
four backup circuits all have a reliability of .90.
a) What is the reliability of the new temperature controller?
b) If you pay a premium, Wing says he can improve all four of the backup units to .93.
What is the reliability of this option?

Problem 17.17
The fire department has a number of failures with its oxygen masks and is evaluating the
possibility of outsourcing preventive maintenance to the manufacturer. Because of the risk
associated with a failure, the cost of each failure is estimated at $2,000. The current
maintenance policy (with station employees performing maintenance) has yielded the
following history:

Number of breakdowns 0 1 2 3 4 5
Number of years in which
breakdowns occurred 4 3 1 5 5 0

This manufacturer will guarantee repairs on any and all failures as part of a service contract.
The cost of this service is $5,000 per year.
a) What is the expected number of breakdowns per year with station employees performing
maintenance?
b) What is the cost of the current maintenance policy?
c) What is the more economical policy?

Problem 17.18
As VP for operations at Brian Normoyle Engineering, you must decide which product design,
A or B, has the higher reliability. B is designed with backup units for components R3 and R4.
What is the reliability of each design?

Product Design A
R1 R2 R3 R4
0.99 0.95 0.998 0.995

Product Design B
R1 R2 R3 R4
0.99 0.95 0.985 0.99

0.95 0.99