Given Information : Owner : George Brown started the Old Oregon Wood Store to ma

Question

Given Information :

Owner : George Brown started the Old Oregon Wood Store to manufacture Old Oregon tables.

Each table is carefully constructed by hand using the highest quality oak.

Old Oregon tables can support more than 500 pounds, and since the start of the Old Oregon Wood Store, not one table has been returned because of faulty workmanship or structural problems.

In addition to being rugged, each table is beautifully finished using a urethane varnish that George developed over 20 years of working with wood-finished materials.

The manufacturing process consists of four steps:

preparation, assembly, finishing, and packaging.

One person performs each step.

In addition to overseeing the entire operation, George does all of the finishing.

Tom Surowski performs the preparation step, which involves cutting and forming the basic components of the tables.

Leon Davis is in charge of the assembly

Cathy Stark performs the packaging.

Although each person is responsible for only one step in the manufacturing process, everyone can perform any one of the steps.

It is George's policy that occasionally everyone should complete several tables on his or her own without any help or assistance.

A small competition is used to see who can complete an entire table in the least amount of time.

George maintains average total and intermediate completion times.

The data are shown in following table.

Table 1
Manufacturing Time in minutes
Tom   Preparation   100   Assembly   160   Finishing   250   Packaging   275
George   Preparation   80   Assembly   160   Finishing   220   Packaging   230
Leon   Preparation   110   Assembly   200   Finishing       Packaging   290
Cathy   Preparation   120   Assembly   190   Finishing   290   Packaging   315
Table 2
Manufacturing Time in minutes
Randy   Preparation   110   Assembly   190   Finishing   290   Packaging   300
Question# 1: What is the fastest way to manufacture Old Oregon tables using the original crew? How many could be made per day?

Answer :

Fastest way to manufacture table as per the original table .

Select the minimum timing as well as alignment of each process.

Table 3
Manufacturing Time in minutes
Tom           Assembly   160              
George   Preparation   80                      
Leon                           Packaging   290
Cathy                   Finishing   290      
Consider the 8 hours shift , in 8 hours shift there are 480 min.

The maximum time required for finishing is 290 min.

So 480 / 290 = 1.66 no

So if they take a over time of 100 min then 2 tables can be manufactured , but it seems difficult from cost point of view.

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Question #2: Would production rates and quantities change significantly if George would allow Randy to perform one of the four functions and make one of the original crew the backup person?

Answer :

If we see above table no 3 & compare with Randy's fig which are mentioned in . , then Randy's fig. are more .So its of no use to use Randy as a replacement other wise production will be hampered & the costs will be increased.

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Question #3: What is the fastest time to manufacture a table with the original crew if Cathy is moved to either preparation or finishing?

Answer :

Table 4
Manufacturing Time in minutes
Tom                   Finishing   250      
George                           Packaging   230
Leon           Assembly   200              
Cathy   Preparation   120                      
Consider the 8 hours shift , in 8 hours shift there are 480 min.

The maximum time required for finishing is 250 min in table 4 for operation finishing by TOM.

So 480 / 250 = 1.92 no

So if they take a over time of 20 min then 2 tables can be manufactured , Compare to table no 1 cost can be minimized & production will increased .

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Explanation / Answer

The manufacturing process consists of four steps: preparation, assembly, finishing, and packaging. Each step is performed by one person. In addition to overseeing the entire operation, George does all of the finishing. Tom Surowski performs the preparation step, which involves cutting and forming the basic components of the tables. Leon Davis is in charge of the assembly, and Cathy Stark performs the packaging.

Although each person is responsible for only one step in the manufacturing process, everyone can perform any one of the steps. It is George’s policy that occasionally everyone should complete several tables on his or her own without any help or assistance. A small competition is used to see who can complete an entire table in the least amount of time. George maintains average total and intermediate completion times. The data are shown in Figure 15.7.

Packing

Figure 15.7 Manufacturing Time in Minutes

It takes Cathy longer than the other employees to construct an Old Oregon table. In addition to being slower than the other employees, Cathy is also unhappy about her current responsibility of packaging, which leaves her idle most of the day. Her first preference is finishing, and her second preference is preparation.

In addition to quality, George is concerned with costs and efficiency. When one of the employees misses a day, it causes major scheduling problems. In some cases, George assigns another employee overtime to complete the necessary work. At other times, George simply waits until the employee returns to work to complete his or her step in the manufacturing process. Both solutions cause problems. Overtime is expensive, and waiting causes delays and sometimes stops the entire manufacturing process.

To overcome some of these problems, Randy Lane was hired. Randy’s major duties are to perform miscellaneous jobs and to help out if one of the employees is absent. George has given Randy training in all phases of the manufacturing process, and he is pleased with the speed at which Randy has been able to learn how to completely assemble Old Oregon tables. Randy’s average total and intermediate completion times are given in Figure 15.8.

Figure 15.8 Randy’s Completion Times in Minutes

Discussion Questions

What is the fastest way to manufacture Old Oregon tables using the original crew? How many could be made per day?

Would production rates and quantities change significantly if George would allow Randy to perform one of the four functions and make one of the original crew the backup person?

What is the fastest time to manufacture a table with the original crew if Cathy is moved to either preparation or finishing?

Whoever performs the packaging function is severely under­utilized. Can you find a better way of utilizing the four- or five-person crew than either giving each a single job or allowing each to manufacture an entire table? How many tables could be manufactured per day with this scheme?

Prep Assembly Finishing

Packing

Tom 100 60 90 25 George 80 80 60 10 Leon 110 90 80 10 Cathy 120 70 100 25

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