OPIM 101 - Spring 2014

Recitation 3 Exercise - Solutions

Section#(201,202,,214):_____________

Instructor(circle): CostaCentena FraserLiuMishraPrasadWeiden

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Amachinemakestwocomponents,callthemtypeAandB.Ittakes250secondstoswitchproduction
betweenthecomponenttypes.Duringthattimenoproductionoccurs.Wheninproduction,eachunitof
A or B requires 0.5 seconds to be completed. The two components, A and B are combined in an
assemblyprocesstomakeafinalproduct,callitC.Theassemblystepcancombinethetwocomponents
into1unitattherateof40unitsperminute.

Q1AcomponentpairisoneunitofAandoneunitofB.Themachinerotatesbetweenmaking1500
unitsofAandthen1500unitsofB.Whatisthecapacityofthemachineincomponentpairsperminute.

45
Totaltimetoproduce1500unitsofAand1500unitsofB=250stosetupA+750sto
produceA+250stosetupB+750stoproduceB=2000s

Componentspersecond=1500/2000=3/4.

Componentsperminute=3/4x60=45

Q2Iftheproductionschedulecouldbeadjustedwiththegoalofminimizinginventoryintheprocess,
howmanyunitsofAshouldbeproducedbeforeswitchingtocomponentB?Assumethesamenumber
ofunitsofBwouldbeproducedaswell.
Assemblycanproduceat40unitsperminute.Sofindthebatchsizethatproducesat40

unitsperminute. 1000

TheTargetCapacityis40unitsperminute.TheSetupTimeis(250+250)/60=8.33minutes.
TheProcessingTimeis(0.5s+0.5s)/60=1/60minutes

Batchsize=(TargetcapacityxSetupTime)/(1TargetcapacityxProcessingTime)=(40x
8.33)/(140x(1/60))=1000
Q3Supposethemachinerotatesbetweenonebatchof1200unitsofAand1200unitsofB.Inthatcase,
howmuchtime(inminutes)mustthemachinebeforcedidledforeach1200componentsunits
produced?(Forcedidledmeansthemachineisneitherbeingsetuptoproduceorproducing.)

1.67
Assemblyrequires1200/40=30minutestoproduce1200units

Themachinerequires(250+250)/60+1200/60=28.33minutestoproduce1200units.
Soitwillbeforcedtoidle3028.33=1.67minutesduringevery30minuteinterval.

Cadbury has a chocolate factory in Dunedin, New Zealand. For Easter they make two kinds of Easter
Eggs,milkchocolateanddarkchocolate.Thecyclebetweenproducingmilkanddarkchocolateeggs.
Thefollowingtableprovidesdataonthesetwoproducts:

Milk Dark
Demand(lbsperhour) 500 200
Switchovertime(min) 60 30
Productionrateperhour 800 800

Forexample,ittakes30minutestoswitchproductionfrommilktodarkchocolate,butevenmoretime,
60minutes,toswitchfromproducingdarktomilkchocolateeggs(becausethisswitchrequirestheline
to be cleaned more carefully). Demand for milk chocolate is higher (500 lbs per hour vs 200 lbs per
hour)butthelineproducesthematthesamerate(whenoperating),800lbsperhour.
Q4SupposeCadburyproduces2500lbsofmilkchocolateand1000lbsofdarkchocolateineachcycle.
Whatwouldbetheutilization(%)ofthisprocess(thefractionoftimetheprocessisactuallyproducing
product)?
74.47%

Withthisbatchsize,theprocessissupplyconstrainedbecause3500lbsare

producedevery1.5+3500/800=5.875hours,whichisabout3500/5.875=595.74lbsperhour
andthatislessthandemand,whichis500+200=700lbs/hour.Therefore,therewillbenoadditional

idletimebeyondthesetuptime.

Totaltime=5.875hrs

Productiontime=3500/800=4.375hrs
Utilization=4.375/5.875=74.47%

Q5SupposeCadburyproduces2000lbsofmilkchocolateand800lbsofdarkchocolateineachcycle.
Whatwouldbethemaximuminventory(lbs)ofmilkchocolate?
750

2000lbstakes2000/800=2.5hourstoproduce
Duringthattime,inventorybuildsattherateof800500=300perhour

Somaximuminventoryis2.5x300=750lbs

Q6Howmanylbsofmilkanddarkchocolateshouldbeproducedwitheachcycle(abatchofmilkanda
batchofdark)soastominimizeinventorywhilesatisfyingdemand?
8400

Processingtime=1hr/800pounds

Setuptime=1hr+.5hr=1.5hr

Capacity(demand)=500+200=700pounds/hr

Batchsize=(capacityXsetuptime)/(1capacityXProcessingtime)=(700pds/hrX1.5hr)/(1(700pds
X1/800mins)=8400pounds