System physics Exercise

SYSTEM PHYSICS EXERCISES

Exercise 1
Washing Spa is a manufacturing company producing household appliances. Its production system is
composed by 3 production stations decoupled by stocks, whose main characteristics are highlighted
in the table below.

Station 1 Station 2 Station 3

Cycle time 22 sec/pc 25 sec/pc 24 sec/pc
Setup time 10 min 5 min 5 min
Availability 80% 100% 90%

The daily demand is equal to 2000 units. The facility is open 220 days per year, three shifts per day
of seven hours each. The quality control at the end of the line intercepts defective units, which are
equal to 5% of the processed ones. Defective units are scrapped (discarded).
seas
Consider a single-product situation (Washing Spa is producing only 1 product).
1. What is the daily production capacity of Washing Spa ?
2. The company is evaluating the possibility to organize its production system according to a
coupled serial configuration. What would be the daily production capacity of Washing Spa
in this case?

Now, consider a multi-product situation (Washing Spa is producing more than 1 product).
3. Assume that batch size is 60 products and that a setup is required in each station every time
the production of a new batch starts. Is Washing Spa able to meet customer demand
according to its production system decoupled by stocks?
4. Assume that Washing Spa has a product range of 15 finished products and that it is willing
to produce the whole range every day. What would be the maximum setup time if the
production system is organized as a coupled one?

1 Ct25 secpc
1 Danycapacitygeodestation3600 1 0,8 2749,1pelday
2
36821 3024pelday
3 360024210,9 2835
peday
Weseenchoosesereconest productioncapacitybetweenseeStations
BOTENECKSTATION 1
E STATON 2 is the bottleneck s 21 3024
actual 360g pcday
C APACITY C0,80,9 2177,28 pcday
3 DAILY PRODUCTION 60 seeps 60 35setupsperday 2000 2105
SETUPS In sararate
Ta 75600 s
1 220.2105 35 600 756005 78750 75600 NOTVERIFIED

4 TSU X 15

illeg
Operations Management
X –178,88
©All rights reserved S SETUP
Alberto Portioli TIME and Matteo Rossini
Staudacher
 System physics Exercise

Exercise 2

MTCF Spa is a leader in the production of wrist watches.

The company has a daily demand of 3,000 watches. 100% quality control at the end of the line intercepts the
20% of the watches that are not compliant. In each stage, there is one operator that is specialized and full-
time dedicated. setupsconsedoneinparole
The production process consists of three production stages, decoupled by a fair amount of stocks. The
nous
company works on two shifts per day, for 200 days a year. Each shift is 8 hours with two passe
15 min breaks. The
daily demand of the customer is extremely constant in volume, and, if not satisfied, overtime production is
required, because the company does not want to lose demand.
At the paint stage, the watch hands are painted. Each watch has two hands those are assembled on the dial, in
the next production stage. The case assembly stage puts together the painted hands and ensures sealing of the
watchcase. At the band mounting stage, the operator puts together the watchcase and the band. The table
below shows the quantitative data of the production process.

Process Cycle Time (sec.) Changeover (min.) Uptime (%)

Painting of 1 hand 5 0 90%
Case assembly 9 0 80%
Band mounting 10 0 85%

1) With the production parameters in the table, is the company able to avoid the use of overtime if a
single product type is produced?
2) Assume now that the setup times at painting and case assembly stages are not null.
In particular, at the painting stage it is possible to paint the hands with 4 different colors. In each
watch, the hands are same colored. The color change at this stage takes 15 minutes. At the case
assembly, each pair of watch-hands is mounted whit each of the 3 different cases. The set-up time at
the case assembly and closing stage when switching from one case type to another one is 5 minutes.
What is the minimum batch size to meet customer demand without using overtime?
3) In the case MTCF changes to a coupled serial production system, how would be the answer to
question 1?
4) Assume now that MTCF works according to a coupled serial system configuration with availability
equal to 90% for each stage. Same setup times and number of variants explained in question 2 are
here valid. Moreover, the whole range is requested every day. With this configuration is the overtime
necessary to meet daily customer demand? What is the minimum batch size not to use overtime?

Aaa Dayproduction eranoonlygamearenoscraps

imperano3000
pieces
arap20
200.217,5
pannasince cessio s toponanomonas
mancano
auavamy.co
case
assembly sess
sandrontina
a ao
Gtg
tpttsuctaeeasiautyaeca.anegaeacasm.ae
pannastage TpDanyprouaon.at
A zag g 41606,07s
Tarso2.7.5.3000 suos
caseasseray Tpsgg 42187,5
Tasnoos
Bandrovina
stessegiuro.es
size
danzgeggion Baton
painting SAGE
Totsta 45coseups7snoa
41666,67
setus n7
Batosize33,7 273,7274
minimum
pirata scarcestbercuseistererinimurgateresyssene
CASEASSEMBLY
Tatta
nazista.casepDsnao
seas39Management

mind
Operations
minimumBato
size sspbara
3g
©All rights reserved – Alberto Portioli Staudacher and Matteo Rossini
3 coupledsystemwithnochanceovertime
Tatsusta54
caos
tedayproductionci
sineperpiece
comosesanoneaque
enos enon
avatar09.000,850,61261.2
FEASIBILITYGECK61274,5s
sua Notvere
Thecompanyisnotascetaavoidmeuse
ofansinegasueproductiongasinglesystem
a1274.5s 2extranousneededgaseraproduction

Tp 3750
0,93
no 51440s

soperator stage
setuptime per
4 e 5 5 no min caos
51440 con 54000
57440 suono
D57,33minextra
time
needed
MINIMUMBATCHsize
III
snooty usiAveresavane esuono
a
se miasetup
aree8,33
s etup