Question

3. For this question consider hiring another worker and duplicating Operation D as shown in the diagram below. The two workers work on successive products; they don't work on the same product at the same time. The product still requires the five Steps (A, B, C, D, E) Prepare Front Iron Stitch Front & Back Pack 5 Mins./Unit 12 Mins./Unit Prepare Back Iron 4 Mins,/Unit 5 Mins,/Unit 10 Mim/Unit 12 Mins./Unit

1. What is the fastest a rush order of one unit can go through the process?

2. Working 8 hours a day, what is the daily capacity of the process?

3. What is the labor content of a unit?

Answer 1

1.

Fastest rush order time = flow time = Max(10, 5) + 4 + 12 + 5 = 31 minutes

2.

Capacity = # of resource / processing time

So,

Capacity for A = 1 / 5 per minute = 0.2 per minute
Capacity of B = 1 / 10 per minute = 0.1 per minute (minimum)
Capacity of C = 1 / 4 per minute = 0.25 per minute
Capacity of D = 2 / 12 per minute = 0.167 per minute
Capacity of E = 1 / 5 per minute = 0.2 per minute

So, B is the least capacity station and hence is the bottleneck. So, the capacity of the system is 0.1 per minute or 6 per hour. So, in 8 hours, 6 x 8 = 48 units can be produced.

3.

Labor content = Sum of all process steps = 5+10+4+12+5 = 36 minutes