OldTests_F08

OldTests_F08 - MGMT 46000 Spring 2008: Test 1 Old Tests...

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OldTests_F08.doc Page 1 MGMT 46000 Old Tests – Fall 2008 Only problems from tests (no descriptive questions) given during last academic year are included. Spring 2008: Test 1 Question 2 [20 points: 3 + 2 + 4, 3 + 4 + 4] Part (A): Product X is produced using the process shown to the right. Processing times are in minutes . i. What is the capacity of the Stage 1 in units / hr? ii. What would be the productivity of the process, assuming one worker per machine? iii. If you can add machine M5 (of smallest capacity) in parallel either at stage 1 or stage 2, where would you add it and what will be the cycle time of this machine to maximize process capacity? Part (B): Another product (Y) is processed in 2 stages. At stage 1 there are two machines in parallel (M1 and M2); each requires 12 minutes for processing. At stage 2, there is one machine R1; it needs 6 minutes for processing. Consider the schedule represented in the Gantt chart below. M1 1 3 5 7 M2 2 4 6 R1 1 2 3 4 5 6 Time 10 20 30 40 50 Assume that the process becomes stable after the first two jobs. (i) What is the average throughput time for the schedule? Explain . (ii) Calculate the WIP contributions of M1, M2 and R1 and the total WIP and write them in the table shown. (iii) What is the actual cycle time ? Hint: you can use part (i) and part (ii) answers and Little’s formula. Question 3 [20 points Æ 6 + 9 + 5]: Task times are in seconds in the precedence diagram. Task times = 125 seconds. Target cycle time is 35 sec. / unit. Round off efficiency answers to one decimal place . Part (A): List the tasks in RPW order . Tiebreaker: larger task number has higher priority. Task 1 2 3 4 5 6 7 8 9 10 W e i g h t Resource WIP contribution M1 M2 R1 Total Tasks in RPW order 1 3 5 2 4 6 17 14 15 14 7 10 7 8 10 9 12 15 14 6 M1 6 M4 3 M2 8 M3 8 Stage 1 Stage 2
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OldTests_F08.doc Page 2 Part (B): D o line balancing in the table below. Use the priority order given below ( not the RPW order from part A ). Part (C): Another layout for the above problem is shown here. Calculate effective cycle time and the line efficiency. Question 4 [20 points 8+2, 8+2]: Use as many rows as needed (add if required). Aggregate demand and capacity for a plant with four-quarter planning horizon is shown in the table. No shortages are permitted. Beginning inventory (at the end of Q 0 ) is 800. Part (A): 1. Obtain a production plan with “Chase Strategy”. Make separate adjustments for each quarter where the constraints are violated. 2. Explain adjustments here. Part (B): 1. Obtain a production plan with “Level Strategy” . 2. Explain adjustments here. Question 5 [20 points 6+4, 10]: The precedence diagram for a process is shown to the right (task times are in seconds). Assume 7.5 hours per operator per day (and a single shift). Part (A): The process flow diagram below represents the four stations of one assembly line. There is one operator per station. You can set up multiple lines in parallel.
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OldTests_F08 - MGMT 46000 Spring 2008: Test 1 Old Tests...

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