Wallys Widget Warehouse takes orders from 7 A.M. to 7 P.M. The manager wants to

Question

Wallys Widget  Warehouse takes orders from 7 A.M. to 7 P.M. The manager wants to analyze the process and has provided the process flow diagram shown below. There are three steps required to ship a customer order. The first step is to take the order from a customer. The second step is to pick the order for the customer, and then they have to pack the order ready for shipping. Wally promises that every order placed today gets shipped tomorrow. That means that the picking and packing operations must finish all orders before they go home.

Wally wants to figure out the following.

a. What is the current maximum daily output of the process assuming that no one works overtime? Current maximum output   units per day  

b. How long (in hours) will the picking and packing operations have to work if we have a day where the order taker works at his maximum capacity? (Round your answers to 1 decimal place.)

Pick orders           hours

Pack orders         hours

c. Given b, what is the maximum number of orders waiting to be picked?

Maximum number of orders      units

d. Given b, what is the maximum number of orders waiting to be packed? (Round your intermediate calculations to 1 decimal place.)

Maximum number of orders       units

Management is considering doubling the packing capacity (from 70 to 140 orders per hour). Please answer the following based on that change.

e. How long will the picking and packing operations have to work if we have a day where the order taker works at his maximum capacity? (Round your intermediate calculations and final answers to 1 decimal place.)

Pick orders           hours

Pack orders         hours

f. Given e, what is the maximum number of orders waiting to be picked?

Maximum number of orders      units

g. Given e, what is the maximum number of orders waiting to be packed?

Maximum number of orders       units

Explanation / Answer

a ) current maximum daily output of the process

Assumption : No one works overtime

Here we will consider the units that are available at pack order.

At pack order the capacity is 70 customers per hour.

We have total 12 hours.

12 * 70 = 840 Nos

So daily capacity is 840 Nos.

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b) Here in this case ,

Order taker takes a order at rate of 120 / hour , = 120 *12 = 1440

Now Pick orders rate = 90 / hour

Pack order rate = 70 / hour

So for matching to order takers rate

Pick orders =1440-1080 / 90 = 4 hours extra time needs to work.

Pack orders =1440- 840 /70 = 8.57 hours extra time needs to work.

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c)

Orders waiting to be picked

Taker rate = 120/ hour

Picked Rate = 90 / hour

So Waiting to be picked = 120-90

= 30 per hour

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d) Waiting to be packed :

Rate of picking is 90/ hour

Rate of packaging is 70 / hour

So 90 -70 = 20 /hour will be the waiting at packaging

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e)

Here in this case ,

Order taker takes a order at rate of 120 / hour , = 120 *12 = 1440

Now Pick orders rate = 90 / hour

Pack order rate = 70 / hour

So for matching to order takers rate

Pick orders =1440-1080 / 90 = 4 hours extra time needs to work.

Pack orders =1440- 840 /70 = 8.57 hours extra time needs to work.

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f)

Orders waiting to be picked

Taker rate = 120/ hour

Picked Rate = 90 / hour

So Waiting to be picked = 120-90

= 30 per hour

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g) Waiting to be packed :

Rate of picking is 90/ hour

Rate of packaging is 70 / hour

So 90 -70 = 20 /hour will be the waiting at packaging

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