XLRI Jamshedpur

Rajiv Misra
PRODUCTION PLANNING AND
CONTROL
Team No
Name of Group Members
!ee "as# pa$e a%d a%s&er #he Ge%era" 'ues#io% #oo(
Name of fi"e #o be mai"ed #o rajiv )*"ri+a,+i% -orma#. /M0PPC0Team X01234 &here
X is #he #eam %o
PROC5!! ANAL6TIC! 7AND/OO8
Prob"em 3. Three !#ep Pro,ess Assi$%me%# 'ues#io%s
Pro,ess 3
To begin, consider the three-step process model in the Process 1 tab. The process is staffed by
three workers: Alice is assigned to step A, Bob is assigned to step B, and Charlie is assigned
to step C. Please answer the !estions below.
1. "hat is the bottleneck of this process#
$. "hat is the cycle time of this process#
%. "hat is the capacity of this process#
&. "hat is the thro!ghp!t time or a r!sh order 'that is, an order arri(ing when the system is
empty that is mo(ed thro!gh the process witho!t delay)#
*. "hat is the labor !tili+ation of each worker#
,. "hat is the a(erage labor !tili+ation of the workers#
Pro,ess 1
-ow that yo! ha(e finished Process 1, consider the same process, b!t ass!me we assign
Betty, an additional worker, to a step B. Betty and Bob are e!ally !alified, and they are
told to split the work of step B 'working sim!ltaneo!sly complete the * min!tes of work on a
!nit in half that time).
1. Before doing any calc!lations, which process metrics wo!ld yo! e.pect to change
relati(e to Process1
$. "hat is the cycle time of this process#
%. "hat is the capacity of this process#
&. "hat is the thro!ghp!t time for a r!sh order 'that is, an order arri(ing when the
system is empty that is mo(ed thro!gh the process witho!t delay)#

*. "hat is the labor !tili+ation of each worker#
,. "hat is the a(erage labor !tili+ation of the workers#
/. "hat ha(e yo! learned#
Pro,ess 9
0ook at Process %, a (ariant of Process 1 ' % workers, Alice does step A, Bob step B, and
Charlie step C). 1owe(er, ass!me that steps A and B can be completed in parallel, as shown
in the process diagram. '23n parallel4 means that Alice can work on her component at the
same time as Bob works on his component. 5or e.ample, Alice co!ld be finishing a table top
at the same time Bob is finishing the fo!r legs, and Charlie co!ld be assembling the table by
attaching the legs to the table top.)
1. Before doing any calc!lations, which process metrics wo!ld yo! Process 3#
$. "hat is the bottleneck of this process#
%. "hat is the cycle time of this process#
&. "hat is the capacity of this process#
*. "hat is the thro!ghp!t time for a r!sh order 'that is an order arri(ing when the system
is empty that is mo(ed thro!gh the process witho!t delay)#
,. "hat is the labor !tili+ation of each worker#
/. "hat is the a(erage labor !tili+ation of the workers#
6. "hat ha(e yo! learned#
Prob"em 1. -our !#ep Pro,ess Assi$%me%# 'ues#io%s
Pro,ess 3
To begin, consider the fo!r 7 step process model in the Process 1 tab.
1. Calc!late the amo!nt of the time it wo!ld take to get a r!sh order thro!gh the process.
1&.* 8in!tes
$. Calc!late the capacity of the process.
1$ per ho!r
%. Calc!late the labor content of the process.
& workers
&. Calc!late the a(erage labor !tili+ation.
/$.*9
Pro,ess 1
5or the process $, ass!me that yo! ha(e hired an additional worker 'i.e., a fifth for the
process). This new worker is cross 7 trained at e(ery step in process 'can perform any of the &
steps or any portion of any of the fo!r steps). 3n(entory is permitted between steps so that the
cross 7trained worker can mo(e aro!nd freely. Ass!me no transportation time in mo(ing from
one step to another.
1. At which step 's) does the worker spend the ma:ority of his or her time#
At steps 1 and &
$. "hat is the impact on performance#
Capacity increases to $; per ho!r from 1$ per ho!r. <tili+ation increased to =,.,/9 from
/$.*9.
Pro,ess 9
5or Process %, yo! ha(e the opport!nity to send each of yo!r fo!r specialists to get additional
training in the other process steps. As a res!lt of this training program, yo! will ha(e fi(e
workers a(ailable to yo!, each one cross-trained at each of the fo!r process steps.
1. "hat benefits do yo! e.pect as a res!lt of this additional training#
Capacity increases to $;.,= per ho!r. <tili+ation increased to 1;;9. Any worker who is free
can work on other stations.
Pro,ess 4
>o to Process &, a (ariant of Process 1. ?o!r analysis was done with the ass!mption that no
in(entory wo!ld be allowed to b!ild !p between steps. Answer these !estions witho!t that
ass!mption.
1. 1ow wo!ld performance change if this restriction were rela.ed# That is, what wo!ld
impact of allowing in(entory to acc!m!late between steps#
-o change beca!se bottleneck is at the first step.
Prob"em 9. !ub Assemb": Assi$%me%# 'ues#io%s
Consider the following process in the Process 1 tab. All steps 'A, B, C, @) are necessary to
create each finished !nit. Aach step employs a single worker who is not cross-trained for any
other processing times listed represent the amo!nt of time each worker spends on a single
!nit. There is not (ariability in processing times.
Pro,ess 3
1. "hat is the fastest that a r!sh order can go thro!gh the process#
$. "orking 6 ho!rs a day, what is the daily capacity#
Pro,ess 1
5or the ne.t two !estions, consider a fifth step added to the process along with a fifth
worker. The fifth step, Btep A, is done after Btep C, and before Bte @, as depicted Process $.
All steps 'A, B, C, @, and A) are necessary to create each finished !nit. Processing times are
shown for each process step.
%. "hat is the fastest that a r!sh order can go thro!gh the process#
&. "orking 6 ho!rs a day, what is the daily capacity#
Prob"em 4. /a#,h Pro,essi%$ Assi$%me%# 'ues#io%s
Consider the following three-step worker- paced line in the Process 1 tab. Aach step employs
a single worker who is not cross- trained for any other step. The set!p represents the amo!nt
of time the worker spends setting ! e machine hatch. -o !nits can be processed d!ring set!p.
The r!n time represents the amo!nt of time it takes the worker to process a single !nit. "hen
a worker completes a batch, he or she hands it off to the ne.t stage.
Pro,ess 3
1. 3f only 1;-!nit batches are prod!ced, what is the a(erage capacity of the process per 6-
ho!r
*%.%, per 6 ho!r shifts. ',.,/ per ho!r)
$. At what batch si+e does the bottleneck mo(e# That is, at what batch si+e are there two
steps that are the bottleneck#
Bottleneck mo(es at the batch si+e of &. Time needed at stations $ and % is same at the batch
si+e of *.
Prob"em ;. Ra%dom <aria#io% Assi$%me%# 'ues#io%s
Consider the si.-step process in the Process 1 tab, where the processing time for each step is
!niformly distrib!ted. Processing times can range from 1$ to 16 min!tes 'any (al!e in that
range is as likely to occ!r as any other in that range).
Pro,ess 3
1. 3f in(entory were permitted to acc!m!late thro!gho!t this process, what impact wo!ld
yo! e.pect on capacity 'as compared to the process witho!t in(entory)#
$. 3f yo! co!ld add one in(entory b!ffer, where wo!ld yo! add it to ma.imi+e capacity#
%. 3f yo! added a second !nit of b!ffer to the same location as the first, what wo!ld be the
incremental impact on capacity of the second !nit as compared with the first !nit#
Prob"em =. I%ve%#or: Assi$%me%# 'ues#io%s
consider the fo!r-step worker paced line in the Process 1 tab. Aach step employs a single
worker who is not cross-trained for any other step. The processing times listed represent the
amo!nt of time each worker spends on a single !nit. There is no (ariability in processing
times. Ass!me that all workers begin to work on the ne.t !nit as soon as they can.
Pro,ess 3
1. Ass!me that in(entory is not permitted to acc!m!late - i.e., a !nit cannot be passed to the
ne.t stage !ntil the worker recei(ing the !nit is ready for it. "hat is the capacity of the
process#
% per ho!r
$. 3f in(entory were allowed to acc!m!late in this process, where wo!ld it acc!m!late#
The in(entory will get acc!m!lated at all the three points beca!se the last station has the
highest task time b!t the other stations before the last one will be blocked beca!se of the high
task time re!ired there.
%. 3f in(entory were allowed to acc!m!late, how wo!ld capacity be affected#
The capacity wonCt be affected beca!se the station with the highest task time is at the last.
&. 3f in(entory were allowed to acc!m!late, how wo!ld a(erage thro!ghp!t time be
affected#
Thro!ghp!t time will not be affected.
5rom this point forward, ass!me that in(entory is not permitted to acc!m!late, and that work
cannot be passed to the ne.t stage !ntil the worker recei(ing the !nit is ready.
*. 3f a fifth worker were added to the process, what wo!ld the ma.im!m capacity be#
Ass!me that yo! can add the fifth worker to anyone of the fo!r tasks, that the worker is
not cross trained to do any of the other tasks and that the fifth worker works at the same
rate as the original worker doing that task.
The worker can be added to the fo!rth station since it is the bottleneck and needs to be
ele(ated. The new cycle time will be 1* min!tes beca!se it is the processing time of the new
bottleneck i.e. the second station.
,. 3nstead, if a fifth worker who was cross 7 trained for all tasks were added to the process,
what wo!ld the new capacity be# Ass!me that this fifth worker inc!rs no tra(el time in
mo(ing between Compare the labor !tili+ation of the worker at Btep 1 in the original
sit!ation 'fo!r workers, no in(entory) and the sit!ation with the addition of the cross-
trained fifth worker from the 5o!r Btep Process problem. 1ow does it change#
CanCt answer
Prob"em >. 8ru%,h: 8reme Assi$%me%# 'ues#io%s
Dr!nchy Dreme, marking its famo!s do!ghn!ts, begins with the three-step process shown in
Process 1. Ene dedicated worker mi.es the do!gh and creates the do!ghn!t shape from it.
Batches of do!ghn!ts from the Bhaping stage are processed in one of two identical machines
in the third step, staffed by one worker each. '3gnore the remaining steps in the process, s!ch
as frying and packing, beca!se they ha(e ample capacity.) Ass!me that all set!ps are done by
the workers. A set!p m!st be performed in each step of the process before e(ery batch. Also,
ass!me that each worker is b!sy d!ring the r!n time of his or her operation.
Pro,ess 3
1. B!ppose that the batch si+e is *; do!ghn!ts. "hat is the capacity in an eight 7 ho!r day#
$. "hat is the a(erage !tili+ation of these fo!r workers#
%. 3f Dr!nchy Dreme decides to change batch si+es, for what range of batch si+es is mi.ing
the bottleneck#
Prob"em ?. Ra%dom <aria#io% &i#h Lo%$ Chai%s Assi$%me%#
Pro,ess 3
5or the processes in this assignment, we will e.plicitly acco!nt for (ariability in process time
with those process times distrib!ted according to a !niform distrib!tion. Th!s, a process time
of * F1 min!tesG!nit indicates that there is e!al probability that the process 'machine or
person) will ha(e a process time of anywhere from fo!r to si. min!tesG!nit. There are no
set!ps.
1. Consider an eight-workstation in-series line, with all workstation processing time at * F1
min!tes per !nit. Allocate $$ !nits of b!ffer capacity to this line so as to ma.imi+e a(erage
o!tp!t. "hat is the best s!ch allocation#
5or the rest of this part, consider fo!r different prod!ction ,lines consisting of in-series
workstations with no b!ffers between stations. The n!mbers !nder e workstation represent
the process time per !nit, in min!tes.
$. Ass!ming that 0ine A has been operating for a while, the e.pected capacity of 0ine A is a.
0ess than , !nits per ho!r
a. 0ess than , !nits per ho!r
b. >reater than , !nits per ho!r
c. , !nits per ho!r
d. Cannot be determined
%. Comparing the !tili+ation of 8achine A$ of 0ine A to that of 8achine B% of 0ine B,
e. A$ has the same !tili+ation as B%
f. A$ has a lower !tili+ation than B%
g. A$ has a higher !tili+ation than B%
h. Cannot be determined
&. Comparing the capacity of 0ine B to that of 0ine C,
i. 0ine C has a higher o!tp!t than 0ine BCs
:. 0ine C has a lower o!tp!t than 0ine BCs
k. 0ine C has an o!tp!t e!al to that of 0ine B
l. Cannot be determined
*. Comparing the capacity of 0ine C to that of 0ine @,
m. The o!tp!t of 0ine @ is lower than line @,
n. The o!tp!t of 0ine @
o. The o!tp!t of 0ine @ is higher than 0ine CCs
p. Cannot be determined
Prob"em @. Re&orA a%d !,rap Assi$%me%# 'ues#io%s
3magine a three-workstation worker-paced line with task times /, ,, and 6 min!tes,
respecti(ely. 3n the pre(io!s problems, a 1;;9 yield was ass!med - i.e., no defects. The
present problem will e.plicitly consider the impact of non+ero defect rates. 3n partic!lar,
ass!me that the first workstation has an 69 defect rate and that the second workstation has a
1$9 defect rate. The third workstation, in contrast, generates no defects. 5or problems 1 to &,
ass!me that all defecti(e !nits are scraped.
Par# A
1. "hat is the capacity of this process#
$. "here is the bottleneck#
%. 3s the !tili+ation of the bottleneck step 1;;9# 3f so, why# 3f not, why not#
&. "hat is the yield of the process 'the ratio of good process)#
Par# /
-ow ass!me that the second workstation feeds its defects to a rework station that performs a
delicate and lengthy task of disassembling the prod!ct and repairing it. Th!s, it re!ires a
relati(ely long time 'here, &; min!tes on a(erage) to fi. defects. There is an in(entory b!ffer
in front of this rework step to accommodate for the !nlikely case that there are se(eral defects
in a row. "hile time- cons!ming, it still is s!ccessf!l only =;9 of the time. "hen rework is
s!ccessf!l, the rework station passes the now- good !nit to the third workstation in the line. 3f
it is not s!ccessf!l, the prod!ct is scrapped.
The third workstation, recei(ing reworked !nits, now has an a(erage task time of = min!tes.
1. "hat is the capacity of this process#
$. "here is the bottleneck#
%. 3s the !tili+ation of the bottleneck step 1;;9# 3f so, why# 3f not, why not#
&. "hat is the yield of the process 'the ratio of good finished prod!ct to items started in
the process)#
Name of Group Members
G5N5RAL 'U5!TION!
If :ou &ere #o assi$% a sma"" pro,ess a%a":sis prob"em for /M Ju%iorsB &ha# &ou"d i#
beB &h: a%d i#s e*pe,#ed a%s&er