A B 1 2 Demand Projections Q3 2020 (actual) 3456789 Ampoules Vials Syringes Product 10 11 Ampoules 12 Vials 13 Syringes 14 15 5 10 C Demand History and Projections Product-wise cycle time D E F G Q4 2020 Q1 2021 Q2 2021 [in lots] 55 20 35 60 65 30 35 40 45 Cycle Time (hours) 60 63 57 665 Cycle time breakup by product and line 15 16 Cycle Time (hours/process) 17 18 19 20 Ampoules Vials Syringes Net lot equivalent rejected in a quarter 21 Product 22 23 Ampoules 24 Vials 25 Syringes 26 27 28 29 30 31 32 33 34 35 36 37 Tubing 6 9 6 Hot-forming Washing Packing 12 18 9 21 9 18 222 24 24 24 Bend tubing Rejects Contamination rejects Glass breakages Air bubbles 1 5.7 3.5 2.8 2.8 3.4 6 3.2 3 5.2 2.8 2.6 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Table of Content Data Exhibit-1 Data Exhibit-2 Data Exhibit-3 Data Exhibit-4 4-step manufacturing process for all 3 products in Fabricadas Tubing #1 Tubing #2 Vials Syringes Ampoules Washing #1 Packing #1 Packing #2 Forming #1 Washing #2 Packing #3 Forming #2 Packing #4 Washing #3 Packing #5 Washing #4 Packing #6 Fabricadas Utilization and Stoppages Weekends and Unit Holidays Planned shutdowns Unplanned shutdowns Tubing #1 115 10 15 Tubing #2 115 10 20 Forming #1 115 10 15 Forming #2 115 10 25 Washing #1 115 10 15 Washing #2 115 10 20 Washing #3 115 10 20 Washing #4 115 10 15 Packing #1 115 10 20 Packing #2 115 10 20 Packing #3 115 10 Packing #4 115 10 Packing #5 115 10 20 Packing #6 115 10 20 5522 15
1- Assume all planned shutdowns and unplanned shutdowns are zero and find the Utilization or Implied Utilization of each station. It is your choice if you want to find U of IU. This part has 3 points out of 10 points.
2- Assume ONLY the unplanned shutdowns are zero and find the Utilization or Implied Utilization of each station (It is your choice if you want to find U of IU). In other words for this part, planned shut downs are what provided to you in the Excel file. It is important how you plan them. Based on your plan, you will get different U or IU. This part has 3 points out of 10 points.
3- Now, let's relax the assumption that unplanned shutdowns are zero. In other words, all planned and unplanned shutdowns are what provided to you in the question. Hint: For this part, you need some knowledge from some other OTM courses. Why? Because we have UNPLANNED SHUTDOWNS. You don't know when they are going to happen. Find the Utilization or Implied Utilization of each station. It is your choice if you want to find U of IU. This part has 2 points out of 10 points.
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