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(1) Assume Far Out switches paint color once per day and then cleans the robot at the end of the day. What is the
total number of chairs produced per day on average?
With 2/3 of Rocking Chairs and 40% or Adirondack Chairs stained, the staining baths could receive up to 24 chairs
per hour from the assembly lines ( 30*2/3 + 10*40%). The painting robot receives the other 16 chairs per hour on
average (40 chairs total  24 chairs to staining).
Given the production schedule for the paint robot, it is running 6 hours per day and notrunning 2 hours per day
(either for cleaning or switching colors). Hence the paint robot can produce 120 chairs per day ( 6*20) , or 15 per
hour on average (120/8). The stain baths operate for 11 hours before they must be changed (330/30). There is a 4
hour time to change the stain baths. Since 330 chairs are produced every 15 hours (11+4), on average 22 chairs are
produced per hour (330/15).
To summarize, the assembly lines can produce 30 Rocking Chairs per hour and 10 Adirondack Chairs per hour. Of
these 40 chairs produced per hour, 24 are sent to staining and 16 are sent to painting. Staining can produce 22 chairs
per hour on average, which is 2 less than it would receive from assembly if assembly worked at full speed. Painting
can produce 15 chairs per hour, which is 1 less than it would receive from assembly if assembly worked at full
speed. Hence, assembly must slow down a bit so that an infinite pile up of chairs is avoided. Overall, Far Out can
produce 22 stained chairs per hour and 15 painted chairs per hour, for a total of 37 chairs per hour (which is 296
chairs per day)
(2) Far Out believes that the staining operation is over worked. They are thinking about painting 80% of the
Adirondack Chairs. If they made this change, how many chairs could they manufacture per day?
Now painting receives 8 Adirondack Chairs per hour and (still) 10 Rocking Chairs per hour, for a total of 18 chairs.
Staining receives 2 Adirondack Chairs per hour and 20 Rocking Chairs for a total of 22. The first question
demonstrated that Far Out's maximum production rate is 15 painted chairs and 22 stained chairs. So they still
produce 15+22 = 37 chairs per hour.
(3) Suppose Far Out did paint 80% of their Adirondack Chairs. What is their maximum chair output per day? In
achieving this maximum output, how frequently do they switch paint colors?
It appears that quality considerations will not let them run bigger batches through the staining operation, so only the
production rate of painting can be improved. Painting can operate at a maximum of 7 hours per day because they are
required to clean the robot each night. This cleaning also allows them to switch colors for the next day. So instead of
switching colors in the middle of the day they could economize on setups and switch colors at the end of day. Seven
hours of production generates 140 painted chairs (7*20) which is 17.5 chairs per hour. So the max output is 17.5
painted chairs and 22 stained chairs, which is 39.5 chairs. (Note that assembly's still must slow down from its max
rate of 40 chairs per hour.)
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This note was uploaded on 07/21/2009 for the course BUAD 311T taught by Professor Vaitsos during the Fall '07 term at USC.
 Fall '07
 Vaitsos
 Accounting, Management

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