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OPIM101 - R3 Exercise - Solutions PDF

This document contains solutions to questions about production scheduling and inventory management for a machine that produces two components. Q1 calculates the machine's capacity in component pairs per minute as 45 when producing 1500 units of each component per batch. Q2 finds that the optimal batch size to minimize inventory is 1000 units if produced to match the assembly rate of 40 units per minute. Q3 determines that with batches of 1200 units, the machine will be forced to idle for 1.67 minutes between each batch.

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134 views3 pages

OPIM101 - R3 Exercise - Solutions PDF

This document contains solutions to questions about production scheduling and inventory management for a machine that produces two components. Q1 calculates the machine's capacity in component pairs per minute as 45 when producing 1500 units of each component per batch. Q2 finds that the optimal batch size to minimize inventory is 1000 units if produced to match the assembly rate of 40 units per minute. Q3 determines that with batches of 1200 units, the machine will be forced to idle for 1.67 minutes between each batch.

Uploaded by

joe91bmw
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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OPIM 101 - Spring 2014

Recitation 3 Exercise - Solutions

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

Instructor(circle): CostaCentena FraserLiuMishraPrasadWeiden

PennCardLastName:

PennCardFirstName:

PennID:

Placeyouranswersintheboxesprovided.

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

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