2. The following table shows an eight-step process. The necessary time for one w

Question

2. The following table shows an eight-step process. The necessary time for one worker to perform the step on one unit is listed as well as the number of workers at each step.

Step

Process Time (min/unit)

Number of workers

Hourly Capacity

Utilization

1

3

3

2

4

3

3

5

3

4

6

5

5

3

2

6

5

4

7

3

4

8

2

1

a. Calculate capacity and utilization for each step, assuming unlimited inputs and demand.

b. What is the hourly capacity of the process as a whole?

c. If demand is 20 units per hour, what is the utilization of Step 7?

d. If the supply of inputs is limited to 15 per hour, what is the utilization of Step 5?

Step

Process Time (min/unit)

Number of workers

Hourly Capacity

Utilization

1

3

3

2

4

3

3

5

3

4

6

5

5

3

2

6

5

4

7

3

4

8

2

1

Explanation / Answer

a)

b) Hourly capacity of the the process is the hourly capacity of bottleneck which is maximum of all the steps i.e. 80

c) Demand = 20 units/ hour

Utilizationof step 7 = flowrate/ capacity

= 20/80

=1/4

d) utilization of Step 5 = 15/40

=3/8

Step Process Time No. of workers hourly capacity utilization 1 3 3 3*60/3 = 60 3/60*60=1/1200 2 4 3 3 * 60/4 =45 4/45*60 = 1/675 3 5 3 3 *60/5 =36 5/36*60 =1/432 4 6 5 5*60/10= 30 6/30*60=1/300 5 3 2 2 *60 /3 = 40 3/40*60=1/800 6 5 4 4 *60/5=48 5/48*60=1/576 7 3 4 4 * 60/3 =80 3/80*60=1/1600 8 2 1 1 * 60/2 =30 2/30*60=1/900

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