A manufacturer uses an automated painting process paint as its products. The pro

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A manufacturer uses an automated painting process paint as its products. The product comes in 4 colors red, orange, blue, and green). The paint line operates 2 shifts per day (i.e. 16 hours/day), 7 days/week. During each shift, the line is down for 2, 15-minute breaks. In addition, there are 2 set-ups on each shift (i.e. 1st shift paints red and orange; 2nd shift paints blue and green products). It takes 15 minutes to set up the machine each time the painting operation changes colors. All maintenance activities are done on the off shift so they do not affect the paint process capacity. The design capacity for the painting process is 12 units/hour. Last week the painting process painted 1095 products.

Based on this information, determine the paint process's (1) Weekly Effective Capacity; (2) Utilization; and (3) Efficiency.

Please show the Calculations. Thanks

A manufacturer uses an automated painting process paint as its products. The product comes in 4 colors red, orange, blue, and green). The paint line operates 2 shifts per day (i.e. 16 hours/day), 7 days/week. During each shift, the line is down for 2, 15-minute breaks. In addition, there are 2 set-ups on each shift (i.e. 1st shift paints red and orange; 2nd shift paints blue and green products). It takes 15 minutes to set up the machine each time the painting operation changes colors. All maintenance activities are done on the off shift so they do not affect the paint process capacity. The design capacity for the painting process is 12 units/hour. Last week the painting process painted 1095 products.

Based on this information, determine the paint process's (1) Weekly Effective Capacity; (2) Utilization; and (3) Efficiency.

Please show the Calculations. Thanks

Explanation / Answer

Available time in each shift

= 8 hours – 2 x 15 minutes break – 2 x 15 minutes for each set up

= 8 hours – 30 minutes – 30 minutes

= 8 hours – 60 minutes ( i.e. 1 hour )

= 7 hours

Available time in a day = 7 hours per shift x 2 shifts = 14 hours

Available time in a week of 7 days = 14 hours / day x 7 days = 98 hours

Given , Design capacity = 12 units/ hour

Therefore , Weekly effective capacity = 12 units/ hour x 98 hours = 1176 units

WEEKLY EFFECTIVE CAPACITY = 1176 units

We will define Utilization as :

Utilization = Actual output / Maximum possible output under ideal condition x 100

We will define maximum possible output as the output produced in a week when shifts run uninterrupted without any break and stoppages.

Maximum possible number of hours in a week = 16 hours / day x 7 days = 112 hours

Maximum possible output in a week = 12 units / hour x 112 hours = 1344 units

Actual output = 1095 units

Therefore , Utilization = Actual output / Maximum possible output x 100 = 1095 / 1344 x 100 = 81.47%

UTILIZATION = 81.47 %

We will define Efficiency as:

Efficiency = Actual output / Weekly effective capacity x 100 = 1095/1176 x 100 = 93.11 %

EFFICIENCY = 93.11%

WEEKLY EFFECTIVE CAPACITY = 1176 units

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