Operations Management
17th Edition
ISBN: 9781259142208
Author: CACHON, Gérard, Terwiesch, Christian
Publisher: Mcgraw-hill Education,
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Question
Chapter 5, Problem 5PA
a)
Summary Introduction
To identify: The bottleneck step in the process.
b)
Summary Introduction
To determine: The capacity of the process.
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Consider the following three-step assembly operation with quality problems. All resources are staffed by one employee.
The first resource has a processing time of 7 minutes per unit.
The second resource has a processing time of 6 minutes per unit.
The third resource has a processing time of 5 minutes per unit. With a 40% probability, the flow unit coming out of the third resource has to be reworked. In that case, the operations at the second and third resources are repeated. You can assume that (a) rework always succeeds (i.e. a unit going through the rework loop will always work after the third resource),and (b) the processing times for units in rework are the same as for regular units.
Where in the process is the bottleneck?
1 point
Step 3
Step 2
Step 1
5.Question 5
Consider the following three-step assembly operation with quality problems. All resources are staffed by one employee.
The first resource has a processing time of 7 minutes per unit.
The second resource has a processing time of 6 minutes per unit.
The third resource has a processing time of 5 minutes per unit. With a 40% probability, the flow unit coming out of the third resource has to be reworked. In that case, the operations at the second and third resources are repeated. You can assume that (a) rework always succeeds (i.e. a unit going through the rework loop will always work after the third resource),and (b) the processing times for units in rework are the same as for regular units.
Where in the process is the bottleneck?
Consider the following four-step assembly operation with quality problems. All resources are staffed by one employee.
. The first resource has a processing time of 5 minutes per unit.
. The second resource has a processing time of 6 minutes per unit.
. The third resource has a processing time of 3 minutes per unit. With a 30 percent probability, the flow unit coming out of the third
resource has to be reworked. In that case, the operations at the first, second, and third resources are repeated. You can assume
that (a) rework always succeeds (.e., a unit going through the rework loop will always work after the third resource) and (b) the
processing times for units in rework are the same as for regular units.
• The fourth resource has a processing time of 4 minutes per unit.
a. Where in the process is the bottleneck?
O Step 1
O Step 2
Step 3
Sten 4
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- Consider the following three-step assembly operation with quality problems. All resources are staffed by one employee. The first resource has a processing time of 7 minutes per unit. The second resource has a processing time of 6 minutes per unit. The third resource has a processing time of 5 minutes per unit. With a 40% probability, the flow unit coming out of the third resource has to be reworked. In that case, the operations at the second and third resources are repeated. You can assume that (a) rework always succeeds (i.e. a unit going through the rework loop will always work after the third resource),and (b) the processing times for units in rework are the same as for regular units. For every unit of demand, how many units have to flow through the second step in the process?arrow_forwardConsider 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?arrow_forwardConsider 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?arrow_forward
- Consider the following four-step assembly operation with quality problems. All resources are staffed by one employee. • The first resource has a processing time of 5 minutes per unit. • The second resource has a processing time of 6 minutes per unit. • The third resource has a processing time of 3 minutes per unit. With a 30 percent probability, the flow unit coming out of the third resource has to be reworked. In that case, the operations at the first, second, and third resources are repeated. You can assume that (a) rework always succeeds (i.e., a unit going through the rework loop will always work after the third resource) and (b) the processing times for units in rework are the same as for regular units. • The fourth resource has a processing time of 4 minutes per unit. With this information in hand, answer the following questions: • What is the bottleneck process? • What is the capacity of the process?arrow_forwardA 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…arrow_forwardA 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…arrow_forward
- A machine makes two components; call them types A and B. It takes 250 seconds to switch production between the component types. During that time, no production occurs. When in production, each unit of A or B requires 0.5 second to be completed. The two components, A and B, are combined in an assembly process to make a final product; call it C. The assembly step can combine the two components into 1 unit every 2 seconds, or 30 units per minute. Assume there is ample demand. If the production schedule could be adjusted with the goal of minimizing inventory in the process, how many units of A should be produced before switching to component B? In other words, calculate the optimal batch size for component A. Assume the same number of units of B would be produced as well. answer:_______unitsarrow_forwardA machine makes two components; call them types A and B. It takes 250 seconds to switch production between the component types. During that time, no production occurs. When in production, each unit of A or B requires 0.5 second to be completed. The two components, A and B, are combined in an assembly process to make a final product; call it C. The assembly step can combine the two components into 1 unit every 2 seconds, or 30 units per minute. Assume there is ample demand. Suppose the machine rotates between one batch of 1,000 untis of A and 1,000 units of B. In that case, what is the capacity of the machine in component pairs per minute, where a component pair is one unit of A and one unit of B? answer: __________ component pair per minutearrow_forwardA machine makes two components; call them types A and B. It takes 250 seconds to switch production between the component types. During that time, no production occurs. When in production, each unit of A or B requires 0.5 second to be completed. The two components, A and B, are combined in an assembly process to make a final product; call it C. The assembly step can combine the two components into 1 unit every 2 seconds, or 30 units per minute. Assume there is ample demand. Suppose the machine rotates between one batch of 1,000 unties of A and 1,000 units of B. What is the utilization of the machine? answer: _____percentarrow_forward
- . Consider the following four-step assembly operation with quality problems. Allresources are staffed by one employee.• The first resource has a processing time of 5 minutes per unit.• The second resource has a processing time of 6 minutes per unit.• The third resource has a processing time of 3 minutes per unit. With a 30 percent probability, the flow unit coming out of the third resource has to be reworked. In that case,the operations at the first, second, and third resources are repeated. You can assumethat (a) rework always succeeds (i.e., a unit going through the rework loop will alwayswork after the third resource) and (b) the processing times for units in rework are thesame as for regular units.• The fourth resource has a processing time of 4 minutes per unit.a. Where in the process is the bottleneck?b. What is the capacity of the process?arrow_forwardConsider a production line with five stations in serial. The stations have the following process times in minutes (or minutes/unit). Station 1's process time is 9 minutes/unit. Station 2's process time is 10 minutes/unit. Station three has two identical machines, each of which process a unit in 12 minutes (each unit only needs to be processed on one of the two machines). Station 4's process time is 5 minutes/unit. Station 5's process time is 8 minutes/unit. Which station is the bottleneck station? a) Station 3 b) None of the other options c) Station 2 d) Station 5arrow_forwardA machine makes two components; call them types A and B. It takes 630 seconds to switch production between the component types. During that time, no production occurs. When in production, each unit of A or B requires 0.5 second to be completed. The two components, A and B, are combined in an assembly process to make a final product; call it C. The assembly step can combine the two components into 1 unit every 4 seconds, or 15 units per minute. Suppose the machine rotates between one batch of 2,520 units of A and 2,520 units of B. In that case, what is the capacity of the machine in component pairs per minute, where a component pair is one unit of A and one unit of B? Suppose the machine rotates between one batch of 2,520 units of A and 2,520 units of B. What is the utilization of the machine? Suppose the machine rotates between one batch of 2,520 units of A and 2,520 units of B. What is the average inventory of B components? If the production schedule could be adjusted with…arrow_forward
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