Q3 (30 points): Trojan ReLifers refinishes old wood furniture specializing in ch
ID: 414359 • Letter: Q
Question
Q3 (30 points): Trojan ReLifers refinishes old wood furniture specializing in chairs. Their process for refinishing chairs has 8 workers and 4 stations. The firm works 8 hours per day and 5 days per week They process one type of chair: FP-chair (fully processed chair). FP-chairs start at the Stripping station, then go to Priming, then to Painting and finally to Inspection after which they are picked up by the customer. Where there are multiple workers within a station, each worker works independently on his/her own chair. Processing times and worker allocation are given below # workers | Processing time (hours per chair per worker) Station Stripping Priming Painting Inspection 2.5 1.5 1.75 0.8 2 a) (12 points) What are the capacities of each of the 4 stations? Which station is the bottleneck? What is the capacity of Trojan ReLifers in chairs per week? b) (6 points) Suppose now that each worker is (cross-)trained to do all tasks and each worker works on a chair from start to finish, i.e., each worker does Stripping, Priming, Painting and Inspection. What is the maximum capacity of the process in chairs per hour? c) (12 points) Suppose now Trojan ReLifers processes SP-Chairs (semi-processed chair) in addition to FP-Chairs. SP-chairs start at the Stripping Station and then go to the Priming station, after that they are picked up by the customer. Suppose that there is demand for 40 FP-Chairs and 6 SP-Chairs per week, and that there is no cross-training. Which station is the bottleneck? What is the capacity of Trojan ReLifers in chairs per week?Explanation / Answer
a)
Capacity of a station = Available hours per week per worker * # of workers / processing time in hours per chair per worker
Capacity of Stripping station = 40*3/2.5 = 48 chairs per week
Capacity of Priming station = 40*2/1.5 = 53.3 chairs per week
Capacity of Painting station = 40*2/1.75 = 45.7 chairs per week
Capacity of Inspection station = 40*1/0.8 = 50 chairs per week
Minimum capacity is of Painting station. Therefore, it is the bottleneck. Bottleneck capacity is the overall process capacity.
Capacity of Trojan ReLifers = 45.7 chairs per week
b) Total Processing time = 2.5+1.5+0.75+0.8 = 6.55 hours
Total number of workers = 8
Maximum Capacity of the process = 40*8/6.55 = 48.85 chairs per hour
c) Workload on Stripping and Priming stations = 40+6 = 46 chairs per week
Workload on Painting and Inspection stations = 40 FP-chairs per week
Utilization of Stripping station = 46/48 = 95.8%
Utilization of Priming station = 46/53.3 = 85.3%
Utilization of Painting station = 40/45.7 = 87.5%
Utilization of Inspection station = 40/50 = 80%
Stripping station has the highest utilization. Therefore, it is the bottleneck.
Capacity of Trojan ReLifers in-chairs per week is 42 FP chairs and 6 SP chairs
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