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Chapter 4

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56 views2 pages

Chapter 4

Uploaded by

zixuan wei
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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4.3 Assume that each workers need to work 35 hours per week.

a. The bottleneck of the process is the worker of station 3 who is in charge of inserting chips.
b. Capacity=Number of resources/Processing time
So Capacity in toy truck=1/90seconds per truck=40 trucks/hour=1400truks per week
c. Cost of direct labor=Total wages per unit of time / Flow rate per unit of time
=Wages per week / Trucks produced per week
So cost of direct labor=(9*$15*35(hours per week))/1400 trucks per week=$3.4/truck
d. The total working time for a work cell=75+85+90+65+70+55+80+65+80=665seconds
Capacity=1/665 seconds per truck=5.4trucks/hours=189.5trucks per week
Cost of direct labor=(1*$15*35(hours per week))/189.5 trucks per week=$2.8/truck
e. Utilization of worker in station= capacity of the assembly line/ capacity of worker in station 2
=(1/90)/(1/85)=94.4%
f. Worker 1 is in charge of station 1; worker 2 is in charge of station 2;
worker 3 is in charge of station 3; worker 4 is in charge of station 4 and 5;
worker 5 is in charge of station 6 and 7; worker 6 is in charge of station 8and 9.
g. Under this situation, the time workers need to finish their own work are 75,85,90,135,135,145
seconds respectively.
So new capacity of the line=1/145 seconds per truck=24.8trucks/hour=869.0trucks per week.

4.6
a.
The capacity of each step：
Bottling = 60*60/1 = 3600 per hour
Applying a lid = 60*60/3 = 1200 per hour
Labelling = (60*60/5)*2 = 1440 per hour
Packaging = 60*60/4 = 900 per hour
The lowest is the bottleneck and the process capacity is 900 bottles per hour
b.
The bottleneck is the packaging process
c.
There is not going to be any change. This is because the labelling process is not the bottleneck.
The overall process capacity is not going to change.
d.
The utilization will be 60*10/900 = 0.6667 or 66.67%

4.8
a) What is the process capacity in gloves/hour?
Cutting has a process capacity of 1 glove/2 minutes*60 minutes = 30 gloves/hour.
Dyeing has a process capacity of 1 glove/4 minutes*60 minutes = 15 gloves/hour.
Stitching has a process capacity of 1 glove/3 minutes*60 minutes = 20 gloves/hour.
Packaging has a process capacity of 1 glove/5 minutes*60 minutes = 12gloves/hour.
Therefore, the capacity is 12 gloves/hour.
b) Which one of the following statements is true
i. The capacity of the process increases by reducing the dyeing time.
ii. By reducing packaging time, the process capacity increases.
iii. By reducing cutting time, the capacity of the process increases.
Without improving the bottleneck, we cannot improve the whole process. Both i. and iii. are
wrong since dyeing and cutting are not bottlenecks. ii. By reducing packaging time the process
capacity increases is correct because packaging is the bottleneck.
c) What is the utilization of the packaging machine if the demand rate is 10
gloves/hour?
If the demand is 10 gloves/hour, then the utilization at packaging = 10/12 = 83.3%.
d) What is the flow time for a glove?
IT IS AN IMPORTANT DETAIL THAT WE HAVE A CONVEYOR BELT HERE. THE
SPEED NEEDS TO ACCOMMODATE THE BOTTLENECK.
Since bottleneck is the last station, the flow time:
Processing time of bottleneck * # stations = 5*4 = 20mins
(If every station had processing time = 5 then there would be no waiting, so now 20
– 14 = 6 mins spent as waiting time)

Q4.9
Answer: Flow rate =Utilization * Capacity
a. 36/0.4=90 units/h
b. Step4 bottleneck has the smallest capacity so it has the highest Utilization.
c. Step1 bottleneck has the smallest utilization so it has the highest capacity.
d. Cost of direct labor =wages/flow rate= 5*36/36= $5 per units

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