4. Abbott Manufacturing produces plastic cases for solar photovoltaic panels and
ID: 348843 • Letter: 4
Question
4. Abbott Manufacturing produces plastic cases for solar photovoltaic panels and has decided to combine orders from customers to increase work order size, and thereby make one large production run per model type. Plastic injection molding machines are used to make these parts, and it is time consuming to clean the machines and set them up again between production runs. Each molding machine and operator works one 9-hour shift with a one-hour lunch break and one-half hour for operator breaks. CONSOLIDATED WORK ORDERS SETUP (CHANGEOVER) TIME PER WORK ORDER (MINUTES) PROCESSING TIME PER PANEL (SECONDS) WORK ORDER QUANTITY Model XVT-5 Case 9,500 panels 90 Model UYT-3 Case 7,500 Model KLY-6 Case 10,800 2.05 75 1.78 150 4.31 COLLECT STUDYBIT What is the total workload (demand) in hours for this work order mix? How many machines will it take to do this work in 1, 2, or 3 days? How might this process be improved?Explanation / Answer
Total workload = Processing time* Number of panels + Set-up time
Total workload Model XVT-5Case = (9500*2.05)/3600 + 95/60 = 6.90 hours
Note - 3600 to convert seconds into hours
Using the same formula, Total workload Model UYT-3 Case = 4.95 hours
And Total workload Model KLY-6Case = 15.43 Hours
Total workload for all cases = 6.90 + 4.95 + 15.43 = 27.28 hours
Number of hours available in a day = 9 hours - breaks = 9 - 1.5 = 7.5 hours
Machine required to do work in 1 day = 27.28 / 7.5 =3.63 = ~ 4 machines
Machine required to do work in 2 day = 27.28 / 15 =1.81 = ~ 2 machines
Machine required to do work in 3 day = 27.28 / 22.5 =1.21 = ~ 2 machines
Note - Machine can be a whole number
This process can be improved by improving operator utilization which currently has 1.5 hours of break. This can be cut short to 1 hour. Further, they can follow completion of work in 2 days time. For one day completion, there is a lot of CapEX involved by ordering 4 machines. For 3 days completion, one of the machine would not at capacity and would be underutilized.
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