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Chapter 2: Q160Q (page 160)

Question:The diagram below represents a process where two components are made at stations A1 and A2 (one component is made at A1 and the other at A2). These components are then assembled at station B and moved through the rest of the process, where some additional work is completed at stations C, D, and E. Assume that one and only one person is allowed at each station. Assume that the times given below for each station represent the amount of work that needs to be done at that station by that person, with no processing time variation. Assume that inventory is not allowed to build into the system.

What is the average hourly output of the process when it is in normal operation?

Short Answer

Expert verified

Answer

Theaverage hourly outputof the process in normal operation is 92.3 units/hour.

Step by step solution

01

Step 1: Average Hourly Output

Average hourly outputis the output produced in an hour by the factor employed in the production process. Since it is an hourly measure, we represent the figure in units per hour.

02

Calculating average hourly output:

Given the details about various stations, stations A1 and A2 can work simultaneously, producing two units every 0.7 minutes. It gives an average of 0.35 minutes per unit of output.

The calculations are:

0.3 + 0.4 = 0.7 minutes

0.7/2 = 0.35 minutes per output

Stations B, C, D, and E take 0.75, 0.65, 0.6, and 0.55 minutes, respectively. Station B is the bottleneck, meaning one (1) unit of output will take 0.75 minutes.

So, the hourly rate will be:

60/0.75 = 80 units/hour.

So, the average hourly output is 80 units per hour.

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Most popular questions from this chapter

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?

An initial solution has been given to the following work center layout problem. Given the flows described and a cost of $2.00 per unit per foot, compute the total cost for the layout. Each location is 100 feet long and 50 feet wide as shown in the following figure. Use the centers of departments for distances and measure distance using metropolitan rectilinear distance.

The National State Bank is trying to make sure that it has enough tellers to handle the Friday afternoon rush of workers wanting to cash their paychecks. It is only concerned with the last hour of the day from 4:00 to 5:00 p.m. It takes 5 minutes per customer to be processed by the tellers. The average customer arrivals are shown in the table below.

The bank currently has 8 teller stations, and all are staffed during the Friday afternoon rush hour.

a. What is the current maximum output at the bank during rush hour?

b. Can the bank process all the customers by 5:00 p.m.?

c. What is the maximum waiting time for customers, and what time period does it occur?

A common problem that many drivers encounter is a car that will not start. Create a fishbone diagram to assist in the diagnosis of the potential causes of this problem.

Question: The Sun River beverage company is a regional producer of teas, exotic juices, and energy drinks. With an interest in healthier lifestyles, there has been an increase in demand for its sugar-free formulation. The final packing operation requires 13 tasks. Sun River bottles its sugar-free product 5 hours a day, 5 days a week. Each week, there is a demand for 3,000 bottles of this product each week. Using the data below, solve the assembly-line balancing problem and calculate the efficiency of your solution, assuming the line runs at the cycle time required to meet demand. Use the longest task time for your decision criteria. Use the largest number of following tasks as a secondary criterion.

Task

Performance Time

(Minutes)

Task Must Follow

1

0.1

-

2

0.1

1

3

0.1

2

4

0.2

2

5

0.1

2

6

0.2

3,4,5

7

0.1

1

8

0.15

7

9

0.3

8

10

0.5

9

11

0.2

6

12

0.2

10,11

13

0.1

12
See all solutions

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