1
The​ three-station work cell at Pullman​ Mfg., Inc. is illustrated in the figure below. It has two machines at station 1 in parallel​ (i.e., the product needs to go through only one of the two machines before proceeding to station​ 2). This is equivalent to having two parallel workers at a station.
​a) What is the cycle time of the system in minutes (i.e., time of the bottleneck station)?
) What is the rush order flow time in minutes (flow time with no waiting)?
c) If the firm operates 10 hours per​ day, 6 days per​ week, what is the weekly capacity of this work cell? (give the answer as a whole number).
d) If a second parallel machine is added at station 3, then what is the weekly capacity of this work cell?
2
The​ three-station work cell illustrated in the figure below has a product that must go through one of the two machines at station 1​ (they are​ parallel) before proceeding to station 2.
Remember capacity and processing time are reciprocals of each other.
So if capacity is 10 units/hr, then the processing time is 1/10 of an hour or 6 minutes.
If there are 2 parallel machines (or workers) at a station with capacity of 10/hr, then the processing time at that station is still 6 minutes, but the cycle time (average time between completions) is 3 minutes, and the capacity at that station is 2*10/hr = 20/hr.
​a) What is the hourly capacity of this system?
) What is the cycle time of the system in minutes (i.e., processing time at the bottleneck station)?
c) What is the rush order flow time in minutes (flow time with no waiting)?
d) If the firm operates 10 hours per​ day, 5 days per​ week, what is the weekly capacity of this system? (give the answer as a whole number)
3
cut and shape cut holes XXXXXXXXXXapply cement position and clamp dry XXXXXXXXXXpolish
35.025
Kathy’s Kitchen designs, manufactures, and installs custom kitchen counters. At their manufacturing facility in North Carolina they produce counters with built in kitchen sinks. There are 6 steps in this manufacturing process.
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Step 1: cut and shape the countertop from a section of Granite. It takes one worker 60 minutes to cut one countertop. Five workers work in the cutting area.
Step 2: cut the holes in the countertop for the future placement of the sink bowl and faucets. It takes one worker 90 minutes to cut these holes. Seven workers perform this task.
Step 3: apply cement to appropriate surfaces. There is only one worker there who takes 8 minutes to do this part.
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Step 4: position and clamp a sink bowl under the countertop. It takes one worker 45 minutes to perform this step. There are 3 workers at this workstation.
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Step 5: The cement must dry for 2 hours. (This is not a workstation as no work is being performed.)
Step 6: polish the edges of the top side of the countertop. It takes one worker 45 minutes to polish the edges, and 4 workers are positioned here.
You are given a process flow diagram for the process below.
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a) Calculate the number of units that each workstation can produce per hour and place the result below each workstation in the diagram. (Hint: the capacity at each station = capacity with one worker * number of workers. So the capacity at the first station is 5/hr.)
) State which workstation is the bottleneck. What is its capacity in units per hour?
c) Ignoring startup or shutdown time and assuming that items can move between workstations instantaneously, state here how many units can be completed in a 7.5 hour day.
d) What is the flow time in minutes for the first finished unit? (Remember to include the 2 hours drying time.)
e) Now we will add one worker to the bottleneck workstation that you identified in (b) above. Calculate the new number of units that each workstation can produce per hour and show the calculations and the result below each workstation in the diagram.
f) With the changes made in (e) above, how many units can be completed in a 7.5 hour day?