Q1. (Single-Step Process) Consider a batch flow process with a single step that

Question

Q1.         (Single-Step Process) Consider a batch flow process with a single step that has a setup time of 100 minutes and a processing time of 3 minutes/unit.

a. Assume that the batch size is 50 parts.What is the capacity of the process (in units per hour)?

b. Suppose the batch size is increased to 300 parts.What is the capacity of the process now (in units per hour)?

c. Your company wants to attain a process capacity of 25 units per hour.Is this possible?What is the absolute highest process capacity you can hope for in this system (in units per hour)?

Q2.         (Multi-Step Process) Consider the following batch flow process consisting of three manufacturing steps:

Step

1

2

3

Processing Time (minutes/unit)

2

3

4

Setup Time (minutes)

60

0

0

a. Assume that the batch size is 40 parts.What is the capacity of the entire process (in units per hour)?

b. Suppose the batch size is changed to 20 parts, what is the capacity of the entire process now (in units per hour)?

c. What is the best (optimal) batch size for this process (in units per hour)?

d. An urgent customer order has come in at 9:00 a.m. for 10 parts.What is the earliest time we can promise delivery?Assume a batch size of 40 parts, and that a batch has to stay together in Steps 1 and 2.(In Step 3 the units can leave the system the moment they are completed.)

Step

1

2

3

Processing Time (minutes/unit)

2

3

4

Setup Time (minutes)

60

0

0

Explanation / Answer

Here,

Parts per batch=50 parts

Installation time =100 minute

Processing time =3 minutes

Therefore,

a.

Cycle time = Set Up time + Processing Time

                   =100 + 3

                    =103 minutes

                    =1.71 hr.

Capacity (per time) =

b.

If the batch size increased to 300 parts, then capacity of the process will be

Capacity (per time) =

c.

Here process capacity = 25 units per hour

Cycle time =1.71 hr.

Therefore,

Number of part per batch = Capacity × Cycle time

                                         =25×1.71

                                          =42.75 parts per batch

Thus, company will attain the process capacity of 25 parts /hr. when batch size will be 42.75 parts.

Utilization =  

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