This is a step in a process that is the slowest compared tothe other steps. This step limits the capacity of the process.
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This is a step in a process that is the slowest compared tothe other steps. This step limits the capacity of the process.
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- Consider the following batch-flow process consisting of three process stepsperformed by three machines. Process steps step 1 step 2 step 3 processing time 0.25min./unit 0.20 min./unit 0.15 min./unit setup time 30 min 20 min 45 min Work is processed in batches at each step. Before a batch is processed at a step, the machine atthat step must be set up. (During a setup, the machine is unable to process any product.) Assumethat there is a dedicated setup operator for each machine (i.e., there is always someone availableto perform a setup at each machine.)a. What is the capacity of step 1 if the batch size is 35 parts?b. For what batch sizes is step 1 (2, 3) the bottleneck?Smooth Chin Device Company The Smooth Chin Device Company is a manufacturer of high-end electric razors. These razors are produced using a machine-paced process. For each razor, a tray with components enters the process at the beginning of a conveyor belt. The tray then passes through the six steps (consisting of various tasks) explained in the table below. Workers perform the assembly operations on the moving tray. The last step consists of an inspection of the then fully assembled razor. The activity times of the process are as follows: There are six workers, one at each of the six stations (A-F). They begin their workday at 8:00 a.m. and work steadily until 4:00 pm. (They are replaced with other workers for breaks and lunches, but the production is not slowed or stopped during these times.) Their hourly wage rate is $25 per hour. You can assume unlimited demand. What is the process capacity (you can ignore any start-up or empty system effects), in razors/hour?A 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…
- A 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…Process with Scrap 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?Process with Scrap 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? 1 point
- Process with Scrap 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.For every unit of demand, how many units have to flow through the second step in the process?A process of making chair is described as follows: Stage 1 Seat and back attached Stage 2 Legs attached The production speeds are 15 chairs per hour for Stage 1 and 30 chairs per hour for stage 2. The cycle time of the process is ______minutes. The flow time of the process is ______ minutes.Smooth Chin Device Company The Smooth Chin Device Company is a manufacturer of high--end electric razors. These razors are produced using a machine--paced process. For each razor, a tray with components enters the process at the beginning of a conveyor belt. The tray then passes through the six steps (consisting of various tasks) explained in the table below. Workers perform the assembly operations on the moving tray. The last step consists of an inspection of the then fully assembled razor. The activity times of the process are as follows: Station Tasks A Preparation 1. Lay out chassis [12 sec] 2. Lay out screws [15 sec] 3. Lay out all other components [17 sec] Total time for A: 44 sec B Assembly 4. Perform task AS1 [10 sec] 5. Perform task AS2 [10 sec] 6. Perform task AS3 [20 sec] Total time for B: 40 sec C Assembly 7. Perform task AS4 [14 sec] 8. Perform task AS5 [16 sec] 9. Perform task AS6 [20 sec] 10. Perform task AS7 [5 sec] Total time for C: 55 sec…
- Smooth Chin Device Company The Smooth Chin Device Company is a manufacturer of high--end electric razors. These razors are produced using a machine--paced process. For each razor, a tray with components enters the process at the beginning of a conveyor belt. The tray then passes through the six steps (consisting of various tasks) explained in the table below. Workers perform the assembly operations on the moving tray. The last step consists of an inspection of the then fully assembled razor. The activity times of the process are as follows: Station Tasks A Preparation 1. Lay out chassis [12 sec] 2. Lay out screws [15 sec] 3. Lay out all other components [17 sec] Total time for A: 44 sec B Assembly 4. Perform task AS1 [10 sec] 5. Perform task AS2 [10 sec] 6. Perform task AS3 [20 sec] Total time for B: 40 sec C Assembly 7. Perform task AS4 [14 sec] 8. Perform task AS5 [16 sec] 9. Perform task AS6 [20 sec] 10. Perform task AS7 [5 sec] Total time for C: 55 sec…Process with Scrap Consider the four-step assembly operations with quality problems The first resource has a processing time of 5mins per unit and one employee doing the operration. the second employee resource has a processing time of 4 mins 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 under 20mins per unit. At the fourth and final resource, one operater handles the product. No quality probnlems exist at this step and the processing time is 12mins per unit. Where is the bottleneck Resource 1, 2, 3 or 4Heizer and Render advises that when analyzing and designing processes to transform resources into goods, the followingquestions should be asked:- Is the process designed to achieve competitive advantage in terms of differentiation, response or low cost?- Does the process eliminate steps that do not add value?- Does the process maximize customer value as perceived by the customer?- Will the process win orders?A Time-Function Map is similar to a flow process chart, but with time added to the horizontal axis. With time-function mapping,notes indicate the activities and arrows indicate the flow direction, with time on the horizontal axis. 1. Choose a process within your organization and construct a Baseline Time-Function Map