Operations Management
17th Edition
ISBN: 9781259142208
Author: CACHON, Gérard, Terwiesch, Christian
Publisher: Mcgraw-hill Education,
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Textbook Question
Chapter 3, Problem 4C
The Tesla Model S, one of the most sought-after luxury cars, is produced in Tesla’s Freemont factory in California. The production process can be broken up into the following subprocesses.
Stamping: In the stamping process, coils of aluminum are unwound, cut into level pieces of sheet metal, and then inserted into stamping presses that shape the metal according to the geometry of the Model S. The presses can shape a sheet of metal in roughly 6 seconds.
Subassembly: The various pieces of metal are put together using a combination of joining techniques, including welding and adhesion. This creates the body of the vehicle.
Paint: The body of the vehicle is then moved to the paint shop. After painting is completed, the body moves through a 350° oven to cure the paint, followed by a sanding operation that ensures a clean surface.
General assembly: After painting, the vehicle body is moved to the final assembly area. Here, assembly workers and assembly robots insert the various subassemblies, such as the wiring, the dash board, the power train and the motor, the battery pack, and the seats.
Quality testing: Before being shipped to the customer, the now-assembled car is tested for its quality. It is driven on a rolling road, a test station that is basically a treadmill for cars that mimics driving on real streets.
Overall, the process is equipped with 160 robots and 3000 employees. The process produces some 500 vehicles each week. It takes a car about 3–5 days to move from the beginning of the process to the end.
Imagine you could take a tour of the Tesla plant. To prepare for this tour, draw a simple process flow diagram of the operation.
How many cars are you likely to encounter as work in progress inventory?
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JCL Inc. is a major chip manufacturing firm that sells its products to computer manufacturers like Dell, Gateway, and others. In
simplified terms, chip making at JCL Inc. involves three basic operations: depositing, patterning, and etching.
• Depositing: Using chemical vapor deposition (CVD) technology, an insulating material is deposited on the wafer surface, forming a
thin layer of solid material on the chip.
Patterning: Photolithography projects a microscopic circuit pattern on the wafer surface, which has a light-sensitive chemical like
the emulsion on photographic film. It is repeated many times as each layer of the chip is built.
• Etching: Etching removes selected material from the chip surface to create the device structures.
The table below lists the required processing times and setup times at each of the steps. There is unlimited space for buffer inventory
between these steps. Assume that the unit of production is a wafer, from which individual chips are cut at a later…
Sawing
20 min/unit
Sanding
20 min/unit
Drilling
32 min/unit
Welding
30 min/unit
Assembly
93 min/unit
Assembly
93 min/unit
Assembly
93 min/unit
A production process is shown in the figure above. The drilling operation occurs
separately from, and simultaneously with the sawing and sanding operations.
Welding starts when both drilling and sanding operations have been completed.
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operation). Considering the process times at stations, what is the process time of the
system (in min/unit)?
Quasi-Tech Corporation produces specially machined parts. The parts are produced in batches in one continuous manufacturing process. Each part is custom produced and requires special engineering design activity (based on customer specifications). Once the design is completed, the equipment can be set up for batch production. Once the batch is completed, a sample is taken and inspected to see if the parts are within the tolerances allowed. Thus, the manufacturing process has four activities: engineering, setups, machining, and inspecting. Costs have been assigned to each activity using direct tracing and resource drivers as follows:
Activity
Expected Cost
Activity Driver
Activity Capacity
Engineering
$1,000,000
Engineering hours
5,000 hours
Setups
900,000
Setups
200 setups
Machining
2,000,000
Machine hours
25,000 machine hours
Inspection
800,000
Inspection hours
2,500 inspection hours
Quasi-Tech produces two models: Model C and Model D. The following table…
Chapter 3 Solutions
Operations Management
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