Question

It takes 3 minutes to load and 2 minutes to unload a machine. Inspection and packing...

It takes 3 minutes to load and 2 minutes to unload a machine. Inspection and packing times total 1 minute; travel between machines takes 2 minutes. Machines run automatically for 20 minutes. Operators cost $10 per hour; machines cost $30 per hour. Document all answers completely. Suppose 12 machines are needed to meet the production requirement.

a) Which of the following assignments will minimize the total cost: {4, 4, 4} or {3, 4, 5}?

b) Is there another combination that will be less expensive than either of these two? An explanation/demonstration is required.

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Answer #1

Calculate the ideal number of identical machines assigned to an operator .

…… (1)

Here, is concurrent activity time, is the independent machine activity time, and is the independent operator activity time.

Calculate the concurrent activity time .

Substitute for loading time of machine, and for unloading time of machine.

Substitute for , for , and for in Equation (1), to calculate the maximum number of machines assigned to an operator.

Since fractional number of machines cannot be assigned, take the maximum number of machines that can be assigned to an operator as 4.

Therefore, the maximum number of machines that can be assigned to an operator without creating machine idle time during a repeating cycle is .

Calculate the ratio of cost per operator hour and cost per machine hour.

Here, cost per operator hour is , and cost per machine hour is .

Substitute for , and for .

Write the condition for the machine assignment that minimizes the cost per unit produced.

Here, is the ratio of to .

Substitute for .

Substitute for.

…… (2)

Substitute 0.4 for , 4 for , and 4.166 for in Equation (2).

Since the value of is less than 1, take maximum number of machines that can be assigned to an operator without creating machine idle time during a repeating cycle as 4.

Therefore, an assignment of will minimize the cost per unit produced.

Calculate the cost per unit produced when 4 machines are assigned to an operator.

...... (3)

Substitute 4 for , for , for , 4 for , 5 minutes for , 20 minutes for , and for in equation (3).

Therefore, the cost per unit produced when 4 machines are assigned to an operator is .

For the optimum assignment equal to four, consider the case.

Case (1)

At : :

Substitute for .

…… (4)

Calculate the ideal number of identical machines assigned to an operator .

Substitute for , and for .

Substitute 0.4 for , 4 for , and for in Equation (4).

Rewrite the equation to calculate the value of .

…… (5)

Case (2)

At :

Substitute 0.4 for , 3 for , and for .

Rewrite the equation to calculate the value of .

…… (6)

Therefore, observe the Equations (5) and (6), and note the optimum assignment of 4 machines occurs between the range of .

Alternative 1

Let 15 machines needed to meet the production requirement be divided in 3 parts as .

Calculate the repeating cycle time of 5 machines assigned to an operator.

Here, is the number of identical machines assigned an operator.

Substitute 5 for , for , and for .

Calculate the cost per unit produced .

Here, is the set of divided machine in alternative 1, is the number of machine parts in alternative 1, is the number of machines, and is time 1 hour.

Substitute for , 3 for , for , 15 for , for , 30 minutes for , and for .

…… (7)

Alternative 2

Let 15 machines needed to meet the production requirement be divided in 4 parts as .

As the majority of 4 number of machines assigned to an operator is greater compared to 3 machines assigned to an operator, consider the repeating cycle time of 4 machine to calculate the cost per unit produced by alternative 2.

Calculate the repeating cycle time of 4 machines assigned to an operator.

Here, is the number of identical machines assigned an operator.

Substitute 4 for , for , and for .

Calculate the cost per unit produced .

Here, is the set of divided machine in alternative 2, and is the number of machine parts in alternative 2.

Substitute for , 4 for , for , 15 for , for , 24 minutes for , and for .

…… (8)

Alternative 3

Let 15 machines needed to meet the production requirement be divided in 3 parts as .

Calculate the repeating cycle time of 6 machines assigned to an operator.

Here, is the number of identical machines assigned an operator.

Substitute 6 for , 5 minutes for , and for .

Calculate the average repeating cycle time for alternative 3.

Substitute for , for , and for .

Calculate the cost per unit produced .

…… (9)

Here, is the set of divided machine in alternative 3, and is the number of machine parts in alternative 3.

Substitute for , 3 for , for , 15 for , for , 30 minutes for , and for in equation (9).

…… (9)

Therefore, from Equations (7), (8), and (10), it is observed that machine assignment of is the least costly assignment of 15 machines that gives minimal cost for per unit of production.

Hence, assign the 15 machines in the alternative form of to minimize cost per unit produced.

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Answer #1

Calculate the ideal number of identical machines assigned to an operator .

…… (1)

Here, is concurrent activity time, is the independent machine activity time, and is the independent operator activity time.

Calculate the concurrent activity time .

Substitute for loading time of machine, and for unloading time of machine.

Substitute for , for , and for in Equation (1), to calculate the maximum number of machines assigned to an operator.

Since fractional number of machines cannot be assigned, take the maximum number of machines that can be assigned to an operator as 4.

Therefore, the maximum number of machines that can be assigned to an operator without creating machine idle time during a repeating cycle is .

Calculate the ratio of cost per operator hour and cost per machine hour.

Here, cost per operator hour is , and cost per machine hour is .

Substitute for , and for .

Write the condition for the machine assignment that minimizes the cost per unit produced.

Here, is the ratio of to .

Substitute for .

Substitute for.

…… (2)

Substitute 0.4 for , 4 for , and 4.166 for in Equation (2).

Since the value of is less than 1, take maximum number of machines that can be assigned to an operator without creating machine idle time during a repeating cycle as 4.

Therefore, an assignment of will minimize the cost per unit produced.

Calculate the cost per unit produced when 4 machines are assigned to an operator.

...... (3)

Substitute 4 for , for , for , 4 for , 5 minutes for , 20 minutes for , and for in equation (3).

Therefore, the cost per unit produced when 4 machines are assigned to an operator is .

For the optimum assignment equal to four, consider the case.

Case (1)

At : :

Substitute for .

…… (4)

Calculate the ideal number of identical machines assigned to an operator .

Substitute for , and for .

Substitute 0.4 for , 4 for , and for in Equation (4).

Rewrite the equation to calculate the value of .

…… (5)

Case (2)

At :

Substitute 0.4 for , 3 for , and for .

Rewrite the equation to calculate the value of .

…… (6)

Therefore, observe the Equations (5) and (6), and note the optimum assignment of 4 machines occurs between the range of .

Alternative 1

Let 15 machines needed to meet the production requirement be divided in 3 parts as .

Calculate the repeating cycle time of 5 machines assigned to an operator.

Here, is the number of identical machines assigned an operator.

Substitute 5 for , for , and for .

Calculate the cost per unit produced .

Here, is the set of divided machine in alternative 1, is the number of machine parts in alternative 1, is the number of machines, and is time 1 hour.

Substitute for , 3 for , for , 15 for , for , 30 minutes for , and for .

…… (7)

Alternative 2

Let 15 machines needed to meet the production requirement be divided in 4 parts as .

As the majority of 4 number of machines assigned to an operator is greater compared to 3 machines assigned to an operator, consider the repeating cycle time of 4 machine to calculate the cost per unit produced by alternative 2.

Calculate the repeating cycle time of 4 machines assigned to an operator.

Here, is the number of identical machines assigned an operator.

Substitute 4 for , for , and for .

Calculate the cost per unit produced .

Here, is the set of divided machine in alternative 2, and is the number of machine parts in alternative 2.

Substitute for , 4 for , for , 15 for , for , 24 minutes for , and for .

…… (8)

Alternative 3

Let 15 machines needed to meet the production requirement be divided in 3 parts as .

Calculate the repeating cycle time of 6 machines assigned to an operator.

Here, is the number of identical machines assigned an operator.

Substitute 6 for , 5 minutes for , and for .

Calculate the average repeating cycle time for alternative 3.

Substitute for , for , and for .

Calculate the cost per unit produced .

…… (9)

Here, is the set of divided machine in alternative 3, and is the number of machine parts in alternative 3.

Substitute for , 3 for , for , 15 for , for , 30 minutes for , and for in equation (9).

…… (9)

Therefore, from Equations (7), (8), and (10), it is observed that machine assignment of is the least costly assignment of 15 machines that gives minimal cost for per unit of production.

Hence, assign the 15 machines in the alternative form of to minimize cost per unit produced.

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Answer #1

Calculate the ideal number of identical machines assigned to an operator .

…… (1)

Here, is concurrent activity time, is the independent machine activity time, and is the independent operator activity time.

Calculate the concurrent activity time .

Substitute for loading time of machine, and for unloading time of machine.

Substitute for , for , and for in Equation (1), to calculate the maximum number of machines assigned to an operator.

Since fractional number of machines cannot be assigned, take the maximum number of machines that can be assigned to an operator as 4.

Therefore, the maximum number of machines that can be assigned to an operator without creating machine idle time during a repeating cycle is .

Calculate the ratio of cost per operator hour and cost per machine hour.

Here, cost per operator hour is , and cost per machine hour is .

Substitute for , and for .

Write the condition for the machine assignment that minimizes the cost per unit produced.

Here, is the ratio of to .

Substitute for .

Substitute for.

…… (2)

Substitute 0.4 for , 4 for , and 4.166 for in Equation (2).

Since the value of is less than 1, take maximum number of machines that can be assigned to an operator without creating machine idle time during a repeating cycle as 4.

Therefore, an assignment of will minimize the cost per unit produced.

Calculate the cost per unit produced when 4 machines are assigned to an operator.

...... (3)

Substitute 4 for , for , for , 4 for , 5 minutes for , 20 minutes for , and for in equation (3).

Therefore, the cost per unit produced when 4 machines are assigned to an operator is .

For the optimum assignment equal to four, consider the case.

Case (1)

At : :

Substitute for .

…… (4)

Calculate the ideal number of identical machines assigned to an operator .

Substitute for , and for .

Substitute 0.4 for , 4 for , and for in Equation (4).

Rewrite the equation to calculate the value of .

…… (5)

Case (2)

At :

Substitute 0.4 for , 3 for , and for .

Rewrite the equation to calculate the value of .

…… (6)

Therefore, observe the Equations (5) and (6), and note the optimum assignment of 4 machines occurs between the range of .

Alternative 1

Let 15 machines needed to meet the production requirement be divided in 3 parts as .

Calculate the repeating cycle time of 5 machines assigned to an operator.

Here, is the number of identical machines assigned an operator.

Substitute 5 for , for , and for .

Calculate the cost per unit produced .

Here, is the set of divided machine in alternative 1, is the number of machine parts in alternative 1, is the number of machines, and is time 1 hour.

Substitute for , 3 for , for , 15 for , for , 30 minutes for , and for .

…… (7)

Alternative 2

Let 15 machines needed to meet the production requirement be divided in 4 parts as .

As the majority of 4 number of machines assigned to an operator is greater compared to 3 machines assigned to an operator, consider the repeating cycle time of 4 machine to calculate the cost per unit produced by alternative 2.

Calculate the repeating cycle time of 4 machines assigned to an operator.

Here, is the number of identical machines assigned an operator.

Substitute 4 for , for , and for .

Calculate the cost per unit produced .

Here, is the set of divided machine in alternative 2, and is the number of machine parts in alternative 2.

Substitute for , 4 for , for , 15 for , for , 24 minutes for , and for .

…… (8)

Alternative 3

Let 15 machines needed to meet the production requirement be divided in 3 parts as .

Calculate the repeating cycle time of 6 machines assigned to an operator.

Here, is the number of identical machines assigned an operator.

Substitute 6 for , 5 minutes for , and for .

Calculate the average repeating cycle time for alternative 3.

Substitute for , for , and for .

Calculate the cost per unit produced .

…… (9)

Here, is the set of divided machine in alternative 3, and is the number of machine parts in alternative 3.

Substitute for , 3 for , for , 15 for , for , 30 minutes for , and for in equation (9).

…… (9)

Therefore, from Equations (7), (8), and (10), it is observed that machine assignment of is the least costly assignment of 15 machines that gives minimal cost for per unit of production.

Hence, assign the 15 machines in the alternative form of to minimize cost per unit produced.

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