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Chapter 2: Q 11-2OQ. (page 288)
In a flowchart, what is used to represent a storage activity in a process?
Storage is the act of storing anything, such as in an attic as well as basement.
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Question:Rockness Recycling refurbishes rundown business students. The process uses a moving belt, which carries each student through the five steps of the process in sequence. The five steps are as follows:
Step | Description | Time required per student |
1 | Unpack and place on the belt | 1.0 minute |
2 | Strip off bad habits | 1.5 minutes |
3 | Scrub and clean mind | 0.8 minute |
4 | Insert modern methods | 1.0 minute |
5 | Polish and pack | 1.0 minute |
One faculty member is assigned to each of these steps. Faculty members work a 40-hour week and rotate jobs each week. Mr. Rockness has been working on a contract from General Eclectic, which requires the delivery of 2,000 refurbished students per week. A representative of the human resources department has just called complaining that the company hasn鈥檛 been receiving the agreed number of students. A check of finished goods inventory by Mr. Rockness reveals that there is no stock left. What is going on?
A small barbershop has a single chair and an area for waiting, where only one person can be in the chair at a time, and no one leaves without getting their hair cut. So the system is rough:
Entrance Wait Haircut Exit
Assume customers arrive at the rate of 10 per hour and stay an average of 0.5 hours. What is the average number of customers in the barbershop?
The Goodparts Company produces a component that is subsequently used in the aerospace industry. The component consists of three parts (A, B, and C) that are purchased from outside and cost 40, 35, and 15 cents per piece, respectively. Parts A and B are assembled first on assembly line 1, which produces 140 components per hour. Part C undergoes a drilling operation before being finally assembled with the output from assembly line 1. There are in total six drilling machines, but at present only three of them are operational. Each drilling machine drills part C at a rate of 50 parts per hour. In the final assembly, the output from assembly line 1 is assembled with the drilled part C. The final assembly line produces at a rate of 160 components per hour. At present, components are produced eight hours a day and five days a week. Management believes that if need arises, it can add a second shift of eight hours for the assembly lines. The cost of assembly labor is 30 cents per part for each assembly line; the cost of drilling labor is 15 cents per part. For drilling, the cost of electricity is one cent per part. The total overhead cost has been calculated as \(1,200 per week. The depreciation cost for equipment has been calculated as \)30 per week.
a. Draw a process flow diagram and determine the process capacity (number of components produced per week) of the entire process.
b. Suppose a second shift of eight hours is run for assembly line 1 and the same is done for the final assembly line. In addition, four of the six drilling machines are made operational. The drilling machines, however, operate for just eight hours a day. What is the new process capacity (number of components produced per week)? Which of the three operations limits the capacity?
c. Management decides to run a second shift of eight hours for assembly line 1 plus a second shift of only four hours for the final assembly line. Five of the six drilling machines operate for eight hours a day. What is the new capacity? Which of the three operations limits the capacity?
d. Determine the cost per unit output for questions (b) and (c).
e. The product is sold at \(4.00 per unit. Assume that the cost of a drilling machine (fixed cost) is \)30,000 and the company produces 8,000 units per week. Assume that four drilling machines are used for production. If the company had an option to buy the same part at $3.00 per unit, what would be the break-even number of units?
Question:A processor makes two components, A and B, which are then packaged together as the final product (each product sold contains one A and one B). The processor can do only components at a time: Either it can make As or it can make Bs. There is a setup time when switching from A to B. Current plans are to make 100 units of component A, then 100 units of component B, then 100 units of component A, then 100 units of component B, and so forth, where the setup and run times for each component are given below.
Component Setup/Changeover Time Run Time/Unit
A 5 minutes 0.2 minute
B 10 minutes 0.1 minute
Assume the packaging of the two components is totally automated and takes only two seconds per unit of the final product. This packaging time is small enough that you can ignore it. What is the average hourly output, in terms of the number of units of the packaged product (which includes one component A and one component B)?
Question: The following represents a process used to assemble a chair with an upholstered seat. Stations A, B, and C make the seat; stations J, K, and L assemble the chair frame; station X is where the two subassemblies are brought together; and some final tasks are completed in stations Y and Z. One worker is assigned to each of the stations. The line is paced using a countdown clock to synchronize production at each station.
Generally there is no inventory kept anywhere in the system, although there is
room for one unit between each of the stations that might be used for a brief amount of time.
Given the following amount of work in seconds required at each station:
a | 38 | j | 32 | x | 22 |
b | 34 | k | 30 | y | 18 |
c | 35 | l | 34 | z | 20 |
a. What is the possible daily output of this 鈥減rocess鈥� if 8 hours of processing time is available each day?
b. Given your output rate in part (a), what is the efficiency of the process?
c. What is the flow time of the process?
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