For this question consider hiring another worker and duplicating Operation D as

ID: 343493 • Letter: F

Question

For this question consider hiring another worker and duplicating Operation D as shown in the diagram below. The two workers work on successive products; they don’t work on the same product at the same time. The product still requires the five Steps (A, B, C, D, E).

What is the throughput time of the very first unit?

Working 8 hours a day, what is the daily capacity of the process? Where is the bottleneck now? What is the cycle time?

What is the amount of time needed to make one unit? (Imagine one person doing all of the above operations).

What is the capacity utilization of each of the 6 people in the above process?

What is the overall capacity utilization of the above process?

Suppose that the two workers currently working on A and B separately, now each do both A and B. What is the impact of this move on the capacity of the process?

Prepare Front Iron Stitch Front & Back Pack 5 Mins./Unit 1 12 Mins./Unit Prepare Back Iron 4 Mins./Unit 5 Mins./Unit 10 Mins./Unit 12 Mins./Unit

Explanation / Answer

1) Total troughout time for first unit is - since all units has to undergo all 5 steps it will take a total of 31mins. since both process a and b can start at the same time, max time to complete both steps is 10 mins, and stiching both portions will take 4 minutes, the ironing and packaging will take 12 and 5 mins respectively so answer is 10+4+12+5 = 31 mins.

2) total working hours in a day will be 8*60 = 480. now to start the process maximum time taken will be 10 mins rest of the steps will go precending so the total time taken to prepare 1 unit will be 10 mins so in 1 day total unit prepared in a day will be 480/10 = 48.

Bottleneck of the process will be at the last stage that is packaging. a place is called a bottleneck where the road becomes narro or where there is lot of traffic, since in our case, at stage D there are 2 persons doing the same job will produce more units and hence there will be rush at the final stage.

3) cycle time will be 31 which is the total time tken to complete 1 batch.

4) Amount of time taken to complete 1 unit when only one person is working will be 36 mins which is 5+10+4+12+5 = 36.

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For this question consider hiring another worker and duplicating Operation D as

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