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Solutions_midterm_S_08

# Solutions_midterm_S_08 - SECTION 2 pm 4 pm PRINT NAME...

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SECTION: 2 pm 4 pm (Circle One) PRINT NAME: SOLUTIONS MARSHALL SCHOOL OF BUSINESS UNIVERSITY OF SOUTHERN CALIFORNIA BUAD 311T: Operations Management For Accounting Majors Professor Ashok Srinivasan MIDTERM EXAM-1 Fall 2008 QUESTION POINTS 1 ________ out of 21 2 ________ out of 12 3 ________ out of 17 4 ________ out of 20 5 ________ out of 10 6 ________ out of 20 TOTAL ________ out of 100 This exam consists of 6 questions on 14 pages including a cover sheet. The time limit on this exam is 1 hour 50 minutes. Answers should be concise and be confined to the space provided below the question. If calculations are involved, please show your work and make sure to that your final answer is clearly visible.

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2 1) Leven Soaps (21 points) Leven is a manufacturer of bars of hand soap. They make two sizes of the soap: a 100-gram size and a 200-gram size—the production process is as follows. First, the (liquid) ingredients of the soap are mixed together in a large container— the company currently mixes in batches of 100 kilograms at a time, regardless of the size bars being made. Once a batch is mixed, the soap is poured into molds of either 100-gram bars or 200- gram bars. (Any given batch is made up entirely of one kind of bar.) In the process of pouring the last of the soap into the molds, the mixing container is scraped almost entirely clean so that it is ready to begin the next batch. It takes an average of 40 minutes to mix a batch of soap (regardless of bar size). Pouring can be done at a rate of 200 bars/hour for the 100-gram size, while the rate is 150 bars/hour for the 200-gram size. Cool: After the molds are filled, they enter a cooling area where cool air is blown onto the soap to harden it. Cooling takes 10 minutes for a batch, regardless of the type of bar. Packaging: Finally, after the bars of soap are hardened they leave the cooling area and a single machine automatically removes them from the molds, individually wraps them, and places them in a carton for shipping. (Assume that the company has plenty of molds, so that lack of molds does not limit the process.) Packaging takes 6 seconds/bar for the 100-gram size, and 10 seconds/bar for the 200-gram size. a) (5 points) Draw a process flow diagram clearly indicating processes and inventories. Mix & Pour Cool Package
3 b) (12 points) Suppose the company wants to make twice as many bars of the 100-gram size as they do of the 200-gram size. What is the processing rate (in bars per hour) of each work station in the system? Cycle = 1 batch of 1000 100-gram bars, then 1 batch of 500 200-gram bars This yields a 2 to 1 ratio of 100-gram bars to 200-gram bars Total time = 40 min. mix + 5 hrs. pour + 40 min. mix + /hr bars 150 bars 500 = 340 min. + 240 min = 580 min L CT=580/1500 min/bar Total work = 1500 bars Processing rate = min 580 bars 1500 x 60 hr min = 155.17 bars/hr Alternately, CT for 100 gm bars= (40 min. mix + 300 min pour)/1000 = 0.34 min/100 gm bar ( Or = (1/200)*60 min pour time + 40/1000 mix time =0.34 min/100 gm bar)

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Solutions_midterm_S_08 - SECTION 2 pm 4 pm PRINT NAME...

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