Consider the batch-flow process consisting of three process stages performed by

Question

Consider the batch-flow process consisting of three process stages performed by three machines:

Work is processed in batches at each stage. Before a batch is processed at Stage 2, the machine in stage 2 has to be set up. During a setup, this machine is unable to process any product. However, for machines in Stage 1 and Stage 3, no setup is required.

a. Assume that the batch size is 100 parts. What is the capacity of machine in Stage 2?

b. Continue with the setting of 100 parts in a batch. Which machine is the bottleneck in this process? What is the process capacity?

c. Now we change to a batch size of 10 parts. Which Stage is the bottleneck of the process? What is the process capacity?

Stage 1 Stage 2 - Stage 3 Activity Time: 5 min/part No Setup Activity Time: 3 min/part Setup time: 20 min Activity Time: 2 min/part No Setup

Explanation / Answer

a) Capacity=Batch-Size / (Setup time + Batch Processing time), So for Step 2: 100/(20+3*100)= 100/320=0.3125 parts per min. OR 18.75 parts per hour b) Step 1 capacity= 100/(0+5*100)=0.2 parts per min, OR 12 parts per hour. Step 3 Capacity= 100(0+2*100)=0.5 parts per min. OR 30 parts per hourFrom the above calculations, it is dear that Step 1 process has the minimum production capacity per hour Therefore, it would act as the bottleneck process Hence, the total capacity of the firm is 12 units per hour. C) when the batch size is 10, Step 1 Capacity=10/(0+5*10)=10/50= 0.2 parts per min OR  12 parts per hour. Step 2 capacity= 10/(20+3*10)= 0.2 parts per min OR  12 parts per hour, Step 3 capacity= 10(0+2*10)= 0.2 parts per min OR  12 parts per hour. When the batch size is 10, there is NO bottleneck and hence the process capacity is 12 parts per Hour

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