PRODUCTION OPERATIONS MANAGEMENT NUMERICAL EXERCISE

L Thetable below shows job consisting 3 sub-jobs b andc along time a of a, with
estimates.
Job
L-2 1

a (davs) b (days)
c (days)

1-6 2

2-2
2

2-4
2

4-5

5-B
5

7-8

7
10

5
L4

r4
26

5 8

5
17

B
2q

3 3 9

8
17

r9

a) Draw the project network diagram. b) Find the critical path and the time takenfor completingthe project. \44ratis the probability of completingthe project in 40 days? 2. A project has the following activities, duration, costs and precedence relationships.
Activity a

Immediate Duration (weeks) predecessorNormal Crash 10 o9

13

Cost(Rs) Normal Crash

11,OOO 2O,OOO 15,OOO 25,OOO 2O,OOO

b
c

d
e f

a a
c

10 20

o6
18
10

9,OOO
25,OOO

30.ooo
35,oOO 30.ooo
25,OOO

b
f

t7
L2 10

20,ooo 20.ooo
15,OOO 12.OOO

h
I

d,f

o9
07

OB

18.ooo
15.OOO

s,h

o8

10,ooo

(a) Draw a CPM network diagram for normal time estimates of activity duration. Calculate the earlieststart, earliestfinish, latest start, latest finish and slackfor eachactivity (b) Determinethe critical path and the duration of completion of project (c) Developcost-timetmde off analysis. Crashthe project to its minimum durationat the lowestcost.

ABCanalysis thefollowingsample itemsin aniaventory. on 3. Perform of Item Annualconsumption Price/unit o 20 ooo

B
D

29oo

C
E F G H I
J

4
4

o
12oo

2
1

30
10

o g2o 2So 9oo 7oo

0

o 02 10 10 go
0

4. Jayceepotteries manufacturescerarnicbowls and mugs. T\vo main used by the companyare skilled labour and clay. The resourcesreq the profit per unit of eachproduct is tabulatedbelow. Product

Resourcesrequired Labour Clay (Hrs/unit) (Kc/unit)

I

Profit /

Bowl Mug

+ 3

There are 4o hours of skilled labour and rzokg of clay available Formulate the problem for maximization of profit as a linear problem and find the solution graphicallyusing iso-profit lines. There are five jobs each of which must go through two machinesA order AB. Processingtime are given below. Assigns the jobs to minimize processing time. Find the idling time of the machines. Job B Machine A 5
I

B ln to

Machine B
6

c
D

3
LO

7 I

jobs to be processed threemachines 6. The processing time in hoursof seven on M1,M2, and M3 aretabulated below. Job B
M1 1 3 M2

c
D E F G

7 3
2

M3 8
10

7 9 4 5
2

B 8 6

9
11

r4
12

Sequencethese job's using Johrson's method and find the overall processing time.Find alsothe waitingtime ofthe threemachines. is how he shouldassign four jobs to the 7. A productionsupervisor considering performed, four of the workersworking under him. He wantsto assign be to ihe jobs to workerssuchthat ihe aggregate time to performjobs is the least. Based the previousexperience, hasthe inforrnation the time takenby on he on the four workers in performing thesejobs asgivenin the tablebelow.Help him in assigning thejob soast]le time takento performthejob is the least. Workers
1

Job

45 57 49
4L

B 4o
42

c
6s

D 67
64 55

48
60

B . A companyhas receivedorder from a large companyto manufacturefive (J1to J5).All thejobsrequireprocessing same components on t),peof jobs on themachines machine. processirg The time (in minutes)ofthe various from past experiences givenin the tablebelow. are Machines M1 Job
J1
L2 10 L7

M2 1B
10

Mg
11

M4
22

M5 r6
20 10

8
15 1g 20

r8
2l

J4

9
13

7
t2

r1
l7

Assign the jobs to machines such that the total processing time is the minimum. Alsofi-nd totalprocessing of lhejobs. the time

9.

Thetablebelowgivesdetailsaboutvarious tasks assembly in operation. Task Precederrce Task tin

Requirement A
D

(minutes) 1
2

0
0

C D
E F G
I

A 4
A B D

3 c
l 2 l
F,H

( 1 5

)
o c o
$

Questions (a) Explain the heuristic stepsinvolved (b) Find the theoreticalminimum cycletime. (c) Find the theoreticalnumber of work stations (d) Assigntasksto work stationsusing LOT rule (e) Calculatethe efEciency the assembly of line (fl Determinethe balancedelay 10.A companyis settingup an assembly to produce192units per I line shift. The following table identifies the work elements,times, and immediate Dreoecessors.

Work element
B D E F H I J

Tirne(seconds) 4o 8o 3o
20 120 L45 130

Irnrnediate Predecessors( D,E,F

If

7zo seconds Questions: (a) What is the cycletime/ (b) What is the theoreticalnumber of work stations? (c) Draw the precedence diagram. (d) Determinethe idle time, efEciency, balancedelay. and

11.The amual demandfor a productis 2,oo,ooounits. Annual carryingcostis cost 3o%of the productcost.The purchase of the productis Rs 37.50per unit and eachtime the productis ordered relatedorderingcostis Rs96.00. the (i) Determine EOQ. the

(ii)

(iii)

v{hatare total the variable costs?

What arethe fixedcosts?

rz. Consider the product structure given below pertaining to a product manufactured Oriental Housilg and Seats. by The numbersin parentheses indicates the number of units of term required to assembleone unit of its parent, Use the information alailable in product structure to answer the questions givenbelow

E (2)

C (2)

c (4)

(a) How many units of C are required to manufactureone unit of product A? Did you makeanyassumption computing value in this How much inventory of each componentis required to satisfyinga ft) demandof roo units of the finai productif (i) thereis no stockof finished goods(ii) thereis a stockof30 unitsofthe final product (c) Consider problem(a),Will the computations change thereis somestock if item B? Why and how much? (Hint: Assumethat you have x units of of item B to proceed with the analysis. 13.Micro Devicesmake a memory expansion board for micro-computers. The companyhasthe following ordersoverthe nel'1six months asbelow: Month 1
Month 2
5000 7000

Month 3

Sooo

Month a Month s Month 6

qooo 6ooo

8ooo

Monthlyproductioncapacities Sooounits on regulartime ard looo units are 2ooo units canbe subcontracted eachmonth.Production overtime and up to costare Rs 20 per unit on regulartime ard Rs 2S/- per unit on overtime; the is costper unit for the components contracted Rs 28/-. Inventoryholding sub costs charged the rateof Re1/-unit per month. are at Use transportation model to developa production schedulefor Micro De\,1ces overlhe nextsix mon*rs.

Apperdix_l

^I:l*t/-!oE R STANDARD NoRMATpRoBAEtLrry

DISTRIBUTION (AISO KNOWN AS Z- DISTRTBUTION)

0.08 0.09 0.q239 0.o3lt 0.0359 0.1 0.03t6 0.0.38 OO1t8 0.0517 o0636 0.0675 0.0r1. 0.0753 0.2 0.0t93 0-0832 O-O8'l o.ott0 o.t026 ot06a 0.ll03 o . lt { t 03 0.1lt9 0.t21, o.t255 o.l2t3 ota06 o.taa3 0.rr80 o.l5t 7 o.a o.t55a 0.159t 0.t628 0.t66t o.tz72 0.1908 o.l8rl 0.t879 0_5 o.r9t5 0.t950 0_1985o.20t9 o.?t23 0.2t57 02t90 o.222! 0.6 0.2257 O.2nl 0.2321 o.?357 ' o.?131 024a o.25)7 0.2519 o.1 0,2560 0-26[ 02612 o.2673 o_2761 o.27ia o2423 0.2s52 0.t 0.188r o.,9ro 02t39 o.n67 0.3051 0.3078 .0.3t03 ot 0ll5t 0.3106o32t2 0.3238 0.33t5 o.lB40 0.3365 0.3389 l.o 6.3Jr3 0.!r!8 0316l 03r85 0355r 035r7 0.3599 o.t62l i . t 036i3 d3&5 63666 - oJt08 0i770 o3790 o3ato o.3830 0.38{9 0J86t oJ888 0-3907 0lt2s o39<a o.3962 03980 o399t 0.4015 oaos? o.{0.9 01066 OJOA2 q4099 o., 15 o,4l3l 0.(rat o.al6? o.1t7l o.al72 Q.a20?0.1?2L 0.r236 o.a2ai 0.a265 o.a2r9 o4292 t.5 0.332 0.a3.5 O.a35t O.tl37O' 0.a3820..:9r olau o.ar t8 o.4429 t.6 0.1152 O.aa6j 0.1171 o.a,r8{ 0..195 o.l505 o.r5r5 0..s23 0,a535 o.a5.r5 Oat51 0..56. O.,a5r3 0..i562 0.45?t 0.1599 o.a60a 0,16t6 0 , 1 5 ? 5 0.a633 r.e 0.161t 0 a619 0.1656 0.a661 0.167t 0.a678 0.{686 0.1693 0.,t699 0.r706 o.a?ti o.17t9 0.1126 0.1732 0.4738 0.r7aa o.1tgJ o.af56 o . l t 6 l 41761 2.O o.ar|? 0!778 0.a783 0.1788 o.ar93 0.a798 oa603 0.r808 0 . ( 8 t 2 0.1811 2.1 0.a82r 0_1826 O..8tO 0.a83. 0.a8380.r8r? 0.lta6 o {850 0.485a o-r05/ 2.2 0..861 0..86a o.a68 0.4871 o.1875 0,a878 o.r88l o..88. o.r887 o.ra90 7.3 o.a89l 0.1896 0.1898 .oa90l o.r90a 0.,t906 0.a909 0.t9ll 0.r9ll 2./ o.(9t8 0.920 O_a9220.a925 o..i2t'0.1929 o,{t3l o_1912 O.a9f,,l o_<936 2S 0.at38 o.t9to o.rill o.1913/ 0.19a50.a916 o.a918 o.1919 0.a951 o..(952 2.6 oa953 0.a955 0.a955 o.1957 0.{959 0.1960 o.a96l o.1962 0,a963 0.{965 O.,t966 0..(967 0.a968 0.196901970 o.1971 o..972 0.1973 o.a97a O:a?71 0.1975 0.19r,6 o.tt97l 0_1977 0_4978 ot9r9 o.1in 0.r980 o..r98r o.a98l 0..98? 0.{982 o_.983 o_498t 0.4984 o.at65 OJ9B5 o.1986 o..(986 3.0 0.1947 0.1987O.a987 o.t98a 0.a988 0.a939 oa989 0.1989 o.a9m 0.a990 *:: ,T -*. b.r{.^ *E h.o^ ond Fi.r 2.25o^ rhc,isnr.i6r h.r or l._1*S l: @n u.ur 6 rh. .iohr, rE_Eru.ortu ,,r.6.<,i6 ot 'hn. *o -r,- i, Oiezb.I *.oo rcru. ond..r or 2.2 o.d ," t*,r,. i.r"i .. . ,1": ,* .L |h.na oddnn brs. :i::T..,f { trd!.r. rh. h.rhodd rh. .oB. *,.n tfi. Eru. roo.s .nd it E 6d ror.o_ rn. 6d _ o* *r,i * ,"r,,-. "n ot Th...t6,. Z - .zii ,r,.",r,.j"i". *.i. * i, ,eor.rtio th. e4 r,o e.r 0.{878bd 'h. ,is. Z h.Gor:(. @td.ri" .*.;" 0 i* y* *. J". .ii.liirl. ii. *1,. ," ih. r.r!kovldi,i t t@.d6, oddj^g roi, b gla 0.5 o"O " FU OOZZa r.,tl.gi, q _U*,n9 a r_. O.S. sr.

0.00

o.ol

o.02

o0

o.omoo.mroo.ooeo 0.0t20

0.03

0.oa O.os 0,06

0,0t60 00t99 0.03570.0596 o.0ta8 o-0t87 o.t33l dt368 0.r700 0.i736 o.2o5r 0.2063 o23A9 0.2122 o,27U 0.2731 02995 0.3023 0t26{ 03289 0.35@ 0.3531 o.3r29 0i719

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