TABLE 4.2 CAPACITY INFORMATION FOR MACON CONTROLS TIME STANDARD DEMAND FORECAST Component Processing (hr/unit) Setup (hr/lot) Lot Size (units/lot) Pessimistic Expected Optimistic A 0.05 1.0 60 15,000 18,000 25,000 0.20 4.5 80 10,000 13,000 17,000 C 0.05 8.2 120 17,000 25,000 40,000 B.

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Macon Controls produces three different types of control
units used to protect industrial equipment from overheating Each of these units must be processed by a machine that
Macon considers to be their process bottleneck. The plant
operates on two 8-hour shifts, 5 days per week, 52 weeks per
year. Table 4.2 provides the time standards at the bottleneck,
lot sizes, and demand forecasts for the three units. Because
of demand uncertainties, the operations manager obtained
three demand forecasts (pessimistic, expected, and optimis-
tic). The manager believes that a 20 percent capacity cushion
is best.a. How many machines are required to meet minimum
(pessimistic) demand, expected demand, and maximum
(optimistic) demand?
b. How many machines are required if the operations man-
ager decides to double lot sizes?

c. If the operations manager has three machines and be-
lieves that the plant can reduce setup time by 20 percent
through process improvement initiatives, does that plant
have adequate capacity to meet all demand scenarios
without increasing lot sizes?

TABLE 4.2 CAPACITY INFORMATION FOR MACON CONTROLS
TIME STANDARD
DEMAND FORECAST
Component
Processing (hr/unit)
Setup (hr/lot)
Lot Size (units/lot)
Pessimistic
Expected
Optimistic
A
0.05
1.0
60
15,000
18,000
25,000
0.20
4.5
80
10,000
13,000
17,000
C
0.05
8.2
120
17,000
25,000
40,000
B.
Transcribed Image Text:TABLE 4.2 CAPACITY INFORMATION FOR MACON CONTROLS TIME STANDARD DEMAND FORECAST Component Processing (hr/unit) Setup (hr/lot) Lot Size (units/lot) Pessimistic Expected Optimistic A 0.05 1.0 60 15,000 18,000 25,000 0.20 4.5 80 10,000 13,000 17,000 C 0.05 8.2 120 17,000 25,000 40,000 B.
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