EBK PRINCIPLES OF OPERATIONS MANAGEMENT
EBK PRINCIPLES OF OPERATIONS MANAGEMENT
11th Edition
ISBN: 9780135175644
Author: Munson
Publisher: VST
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Chapter 9, Problem 15P

The Action Toy Company has decided to manufacture a new train set the production of which is broken into six steps. The demand for the train is 4,800 units per 40-hour workweek:

Chapter 9, Problem 15P, The Action Toy Company has decided to manufacture a new train set the production of which is broken

a) Draw a precedence diagram of this operation.

b) Given the demand, what is the cycle time for this operation?

c) What is the theoretical minimum number of workstations?

d) Assign tasks to workstations.

e) How much total idle time a present each cycle?

f) What is the efficiency of the assembly line with five stations? With six stations?

a)

Expert Solution
Check Mark
Summary Introduction

To draw: The precedence diagram.

Answer to Problem 15P

EBK PRINCIPLES OF OPERATIONS MANAGEMENT, Chapter 9, Problem 15P , additional homework tip  1

Explanation of Solution

Given information:

Task Time (seconds) Immediate predecessors
A 20 -
B 30 A
C 15 A
D 15 A
E 10 B, C
F 30 D, E
Total 120  
  • Weekly demand is 4,800 units / 40 hours workweek.

Precedence diagram:

EBK PRINCIPLES OF OPERATIONS MANAGEMENT, Chapter 9, Problem 15P , additional homework tip  2

b)

Expert Solution
Check Mark
Summary Introduction

To determine: The cycle time.

Introduction:

Cycle time:

Cycle time is the total time taken to complete an unit of work from the beginning of the process to the end of the process.

Answer to Problem 15P

The  cycle time is 30 seconds / unit.

Explanation of Solution

Given information:

Task Time (seconds) Immediate predecessors
A 20 -
B 30 A
C 15 A
D 15 A
E 10 B, C
F 30 D, E
Total 120  
  • Weekly demand is 4,800 units / 40 hours workweek.

Formula to calculate cycle time:

Cycle time=Output / day×60 minutes / hour×60 seconds / minutes

Calculation of cycle time:

Cycle time=404,800×60×60=2408=30seconds / unit

The  cycle time is 30 seconds / unit.

c)

Expert Solution
Check Mark
Summary Introduction

To determine: The theoretical minimum number of workstations.

Answer to Problem 15P

The theoretical minimum number of workstations is 4 workstations.

Explanation of Solution

Given information:

Task Time (seconds) Immediate predecessors
A 20 -
B 30 A
C 15 A
D 15 A
E 10 B, C
F 30 D, E
Total 120  
  • Weekly demand is 4,800 units / 40 hours workweek.
  • Average daily demand is 50 chairs.

Formula to calculate theoretical minimum number of workstations:

Workstations=Total task timeCycle time

Calculation of theoretical minimum number of workstations:

Workstations=12030=4 workstations

The theoretical minimum number of workstations is 4 workstations.

d)

Expert Solution
Check Mark
Summary Introduction

To assign: The different tasks to different workstations.

Explanation of Solution

Assignment of different tasks to different workstations:

Workstation Elligible tasks Selected tasks Task time (seconds) Available cycle time (seconds) Remarks
1 30
A A 20 10 Task A is the only elligible ask
10 (Idle Time) No other elligible task is available
2 30
B, C, D B 30 0 Task B has the highest task time
3 30
C, D C 15 15 Task C is assigned
D D 15 0 Task D is assigned
4 30
E E 10 20 Task E is the only elligible task available
20 (Idle time) The available cycle time is less than the task time
5 F F 30 0 Task F is assigned
Workstation Task assigned Idle time
1 A 10
2 B 0
3 C, D 0
4 E 20
5 F 0
Total 30

e)

Expert Solution
Check Mark
Summary Introduction

To determine: The idle time per cycle.

Answer to Problem 15P

The  idle time is 30 seconds / cycle.

Explanation of Solution

Given information:

Task Time (seconds) Immediate predecessors
A 20 -
B 30 A
C 15 A
D 15 A
E 10 B, C
F 30 D, E
Total 120  
  • Weekly demand is 4,800 units / 40 hours workweek.
  • Average daily demand is 50 chairs.

Calculation of idle time per cycle:

Idle time=10+20=30seconds / cycle

The  idle time is 30 seconds / cycle.

f)

Expert Solution
Check Mark
Summary Introduction

To determine: The efficiency.

Introduction:

Efficiency:

Efficiency is the measure of  what is actually produced as opposed to what can be theoretically produced with the same amount of resources.

Answer to Problem 15P

The efficiency with five and six workstations is 80% and 66.6% respectively.

Explanation of Solution

Given information:

Task Time (seconds) Immediate predecessors
A 20 -
B 30 A
C 15 A
D 15 A
E 10 B, C
F 30 D, E
Total 120  
  • Weekly demand is 4,800 units / 40 hours workweek.
  • Average daily demand is 50 chairs.

Formula to calculate efficiency:

Efficiency=Total task timeNumber of workstations×Cycle time×100

Calculation of efficiency for five workstations:

Efficiency=1205×30×100=12,000150×100=80%

Calculation of efficiency for six workstations:

Efficiency=1206×30×100=12,000180×100=66.6%

The efficiency with five and six workstations is 80% and 66.6% respectively.

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Students have asked these similar questions
To meet holiday demand, Alex's Pie Shop requires a production line that is capable of producing 50 pecan pies per week, while operating only 40 hours per week. There are only four steps required to produce a single pecan pie with respective processing times of 5 minutes, 5 minutes, 45 minutes, and 15 minutes. a. What should be the line's cycle time? b. What is the smallest number of workstations Alex could hope for in designing the line considering this cycle time? c. Suppose that Alex finds a solution that requires only four stations. What would be the efficiency of this line?
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