Kinga Doll Company manufactures eight versions of its popular girl doll, Shari.

Question

Kinga Doll Company manufactures eight versions of its popular girl doll, Shari. The company operates on a 40-hour work week The eight versions differ in doll skin, hair, and eye color, enabling most children to have a doll with a similar appearance to them It currently sells an average of 4000 dolls (spread equally among its eight versions) per week to boutique toy retailers. In simplified terms, doll making at Kinga involves three basic operations: molding the body and hair, painting the face, and dressing the doll. Changing over between versions requires setup time at the molding and painting stations due to the different colors of plastic pellets, hair, and eye color paint required. Table 7.5 lists the setup times for a batch and the activity times for each unit at each step Molding Painting Dressing Process Step Setup time (min) Processing time (min) 0.22 28 No setup 0.2 0.35 (Round your answer to nearest integer.) a. What is the process capacity in dolls per hour with a batch size of 525 dolls? dolls per hour (Round your answer to 2 decimal places.) b. What is the utilization of molding in dolls per hour with a batch size of 900 dolls? 0 (Round your answer to nearest integer.) c. Which batch size would minimize inventory without decreasing the process capacity? dolls per batch Round your answer to nearest integer.) d. Which batch size would minimize inventory without decreasing the flow rate? dolls per batch

Explanation / Answer

a) With a batch of 525 dolls,

Molding time = 10+0.22*525 = 125.5 minutes

Painting time = 28+0.2*525 = 133 minutes

Dressing time = 0.35*525 = 183.75 minutes

Drassing takes the longest time and hence is bottleneck.

Process Capacity = 525 dolls per 183.75 minutes = (525/183.75)*60 = 171 dolls per hour

b) With a batch of 900 dolls,

Molding time = 10+0.22*900 = 208 minutes

Painting time = 28+0.2*900 = 208 minutes

Dressing time = 0.35*900 = 315 minutes

Drassing takes the longest time and hence is bottleneck. Process cycle time = 315 minutes per batch

Process Capacity = 900 dolls per 315 minutes = (900/315)*60 = 171 dolls per hour

Utilization of Molding = Molding time / Process cycle time = 208/315 = 66.03 %

c) The batch size = 28/(.35-0.2) = 187 dolls per batch

d) Flow rate = 4000 dolls / 40 hour = 100 per hour

Let Batch size be x

(x/(28+.2x))*60 = 100

60x = 2800 + 20x

x = 70

Batch size = 70 dolls per batch

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