A production process at Kenneth Day Manufacturing is shown in the figure below.

Question

A production process at Kenneth Day Manufacturing is shown in the figure below. The drilling operation occurs separately from, and simultaneously with, the sawing and sanding, which are independent sequential operations. A product needs to go through only one of the three assembly operations (the operations are in parallel). 1.8 units/hr Sanding Assembly 0.7 units/hr 2.4 units/hr Sawing WeldingAssembly 0.7 units/hr Drilling 5 units/hr Assembly 0.7 units/hr a) Sandingis the bottleneck. b) The bottleneck time is 33.34 minutes per unit (round your response to two decimal places). c) The throughput time of the overall system isminutes(round your response to two decimal places) d) If the firm operates 11 hours per day, 20 days per month, the monthly capacity of the manufacturing process is 396 units (enter your response as a whole number).

Explanation / Answer

In the step 2 , the drilling operation and sanding operation happen simultaneously and a product will be out of this step only when both these operations would be complete. While drilling can handle 5 units per hour , sanding can handle only 1.8 units per hour. Therefore , by virtue of lower processing capacity , sanding operation is the bottleneck operation in step 2. The effective processing capacity of step 2 is thus 1.8 units per hour

Similarly , since step 4 can handle 3 assembly jobs simultaneously , effective processing capacity of step 4 = 0.8 units/ hour x 3 = 2.4 units/hour

Thus effective processing time of various steps as follows :

Step

Operation

Effective processing capacity ( Units/hours)

1

Sawing

2.4

2

Sanding / Drilling

1.8

3

Welding

5

4

Assembly

2.1

Since step 2 has the lowest effective capacity , it is the bottleneck operation

Throughput time ( minutes / item ) will be defined as = 60 /Effective processing capacity

Throughput time of step 1 = 60/2.4 = 25 minutes

Throughput time of step 2 = 60/1.8 = 33.33 minutes

Throughput time of step 3 = 60/5 = 12 minutes

Throughput time of step 4 = 60/2.1 = 28.57 minutes

Throughput time of overall system = 25 + 33.33 + 12 + 28.57 minutes= 98.9 minutes

Available hours in a month = 11 hour/day x 20 days = 220 hours

Monthly capacity of manufacturing process units = 1.8 units/ hour x 220 hours = 396 units

MONTHLY CAPACITY = 396 UNITS

Step

Operation

Effective processing capacity ( Units/hours)

1

Sawing

2.4

2

Sanding / Drilling

1.8

3

Welding

5

4

Assembly

2.1

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