PA 3-4 A small, privately owned Asian company... A small, privately owned Asian
ID: 397186 • Letter: P
Question
PA 3-4 A small, privately owned Asian company... A small, privately owned Asian company is producing a private-label soft drink Yoggo. A bottling line puts the soft drinks into plastic bottles and then packages the botles into boxes holding 10 bottles each. The bottling line is comprised of the following 4 steps: (1) the bottling machine takes 1 second to fill a bottle, (2) the lid machine takes 3 seconds to cover the bottle with a lid, (3) a labeling machine takes 3 seconds per bottle, and (4) the packaging machine takes 4 seconds to place a bottle into a box. When a box has been filled with 10 bottles, a worker tending the packaging machine removes the filled box and replaces it with an empty box. Assume that the time for the worker to remove a filled box and replace it with an empty box is negligble and hence does not affect the capacity of the line. Number of machines Process step Seconds per bottle Bottling Apply a lid Labeling Packaging Bottling Packaging Apply a Lid Labeling The fow diagram is shown above. a. What is the capacity (bottles/hour) at the resource Apply a lid"? 20 bottles per hour b. What is the bottleneck in the process? Packaging c. Assuming unlimited demand, what would be the fow rate? 15 botles per hour d. Assuming unlimited demand, what would be the utilization at percent resource "Apply a lid? Assume the process started empty and that this is a machine- paced process. How long would it take to produce 500 bottles? secondsExplanation / Answer
The capacity( flow rate ) of process will be determined on basis of capacity of the bottleneck step. Bottleneck step is the one which takes maximum time in terms of seconds per bottle.
In the given example, the step which takes maximum time is “Packaging” with time of 4 seconds per bottle.
Therefore, “Packaging” is the bottleneck of the Process
Capacity in terms of bottles/hour at resource “apply a lid”
= 3600 / processing time per second
= 3600 /3
= 1200
Flow rate ( bottles / hour ) = 3600 / Capacity of Packaging = 3600 / 4 = 900
Utilization of resource “apply a Lid”
= Flow rate of the process/ Capacity at the resource “apply a lid” x 100
= 900/1200 x 100
= 75%
Since the process starts empty, amount of time it will take for the bottle to pass through all 4 steps = 1 + 3 + 3 + 4 = 11 seconds
Subsequently amount of time it will take for 500 bottles to come out
= 500 /Flow rate in hour
= 500/900 hours
= ( 500 x 3600 ) / 900 seconds
= 2000 seconds
Total time taken = 11 seconds + 2000 seconds = 2011 seconds = 33 minutes 31 seconds
- Capacity at the resource “Apply a lid” = 1200 bottles/ hour
- Bottleneck in the process : Packaging
- Flow rate = 900 bottles per hour
- Utilization of resource “apply a lid” = 75%
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