Supplemental process problems solutions

Supplemental process problems solutions - SOLUTIONS FOR THE...

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SOLUTIONS FOR THE SUPPLEMENTAL PROCESS ANALYSIS PROBLEMS (rev. 7-8-10) 1. The step in this process with the longest cycle time (the bottleneck) will govern the output; this is step 2 at 1.5 minutes. Therefore, the maximum output from this line, as it is presently configured, will be: Output = (available time)/(cycle time) = (40 hours per week)*(60 minutes per hour)/1.5 minutes per student = 1,600 students per week. (This calculation ignores the throughput time of the first unit processed in a week; since the total task time is only 5.5 minutes per unit, it has no significant impact on the calculation or the answer to the problem.) Therefore, this line cannot produce the 2,000 students per week working 40 hours. Without considering utilization, we could determine the hours of operating time needed to produce the required output. Time needed = (total needed output)*(existing cycle time) = 2000 students * 1.5 min/student = 3000 minutes >>> 50 hours. So the existing line could meet demand by using 10 hours of overtime per week. But, overtime is costly. To avoid overtime, we could calculate the cycle time needed to produce the required output in 40 hours. Needed cycle time = (40 hours * 60 min/hr)/(2000 students) = 1.2 min/student Looking at the task time for each step, we see that our bottleneck, step 2, takes 1.5 min/student; all other steps take 1.2 min/student or less. A quick answer might seem to be that we should add a second person to work step 2 in parallel to the existing person. While this would cut the effective cycle time of step 2 in half (to 0.75 min/student), it does require adding another person (or work station) to the process. Is this really necessary? To answer this question, let’s calculate the optimal number of people (work stations) needed. #work stations = (total task time)/(needed cycle time) = 5.5 min/1.2 min = 4.58 (which we round up to 5) This, in turn, means that we have the right number of people working, we just need to reconfigure the line.
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Supplemental process problems solutions - SOLUTIONS FOR THE...

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