4 A process involves four activities to make a certain product. Activity A needs

Question

4 A process involves four activities to make a certain product. Activity A needs 5 workers and each worker takes on average 1 hour to complete the activity. Activity B is completed through a machine that can process up to 200 units and it takes 5 minutes to process each unit. Once the entire pieces are processed through the machine, it takes 25 hours to dry each set (no matter the number of units in the set). Activity C is completed through a machine that can process up to 200 units. It takes 6 minutes to process each unit and the units (no matter the number of units in the set) will be stained in a kiln for 72 hours. After completing activity C, 4 workers each takes an average of 120 minutes to finish each unit. Assume demand is 1 unit per hour. What is the ideal batch size to minimize inventory while allowing the process to produce at maximum flow rate? Processing Time Setup Time Batch # of workers ze Activity A Activity B Activity C Activity D 60 minutes N/A 5 5 minutes 25 hours 200 6 minutes 72 hours 200 120 minutes 4

Explanation / Answer

Here bottleneck of process is the maximum time taken by activity C. It takes 72 hours to complete the process. Processing time for batch of 200 units in 6 minutes.

So we have to ensure max units place in activity C for 72 hours.

So ideal batch size = 72 * 60 / 6 = 720 units

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