Question 2 (30 pts) A machine has a setup time of 150 minutes and run time of 0.

Question

Question 2 (30 pts)

A machine has a setup time of 150 minutes and run time of 0.0075 minutes per piece. Order sizes are typically 10,000 pieces. After a batch is processed, the process has to be stopped and the machine has to be setup before the next batch can be processed. Assume that a day consists of two shifts and each shift is 450 minutes long.

Find the capacity in pieces per day for this machine under the following assumptions:

(i) A batch can consist of only one order; it cannot have other orders in it. (8 pts)

(ii) Three orders are combined to form a batch. (8 pts)

(iii) All orders can be combined into one batch. (8 pts)

(iv) What is the percent change in capacity as you go from (i) to (ii) to (iii)? (6 pts)

Question 3 (10 pts)

A particular operation may be performed by two kinds of process. Process A requires a setup time of 40 minutes, whereas Process B requires a setup time of 180 minutes. On the other hand, the per unit run times are: 0.015 minutes on A and 0.0023 minutes on B. Which batch sizes would you route to A and which ones to B?

Explanation / Answer

Q2. Given setup time of machine= 150 min

0.0075 min/pc.

1 order =10,000 pcs.

1 day= 2 shifts X 450 min each

10000 pcs per batch before setup required again

(150 min setup time) –> (75 min run time for 10000 pcs) –> (150 min setup time) –> (75 min run time for 10000 pcs) = 450 mins

Total for shift 1 = 20,000 pcs

Similarly, for Shift 2, total production cap = 20,000 pcs

So, total capacity in this case is 40,000 pieces/day

30,000 pcs per batch before setup required again

Shift 1: (150 min setup time) –> (225 min run time for 30,000 pcs) –> (75 min setup time) = 450 mins

Shift 2: (75 min setup time) –> (225 min run time for 30,000 pcs) –> (150 min setup time) = 450 mins

So, total capacity in this case is 60,000 pieces/day

No cap on number of orders in a batch

Shift 1: (150 min setup time) –> (300 min run time for 40,000 pcs) = 450 min

Shift 2: (450 min run time for 60,000 pcs) = 450 min

So, total capacity in this case is 100,000 pieces/day

From (ii) to (iii) there is 66.67% increase in capacity

Q3. For all order batch

                Via Process A: total capacity = (900-40)/0.015 = 860/0.015 = 57,333 pieces/day

                Via Process B: total capacity = (900-180)/0.0023 = 720/0.0023 = 313,043 pieces/day

                So all order batch goes through process B.

Similarly, 3 order batch goes through Process B

And Single order batch goes through Process A.

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