Question

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7. Maruchecks makeshift manufacturing facility had three departments: shaping, pickling, and packing. Maruchecks orders averaged 100 pieces cach. Each of the three shaping machines re- quired one hour setup, but could run a piece in one minute. The pickling department lowered bas- kets of pieces into brine tanks and subjected them to low-voltage current, a heating and cooling. and a rinse. The whole process took four hours for any number of baskets or pieces. The only brine tank could hold four baskets, each of which could contain 50 pieces. (Baskets were loaded while another load was in the tank.) Each piece was inspected and wrapped in bubble pack in the packing department. Each of the four people in the department could do this at the rate of 25 pieces per hour. Marucheck had heard of the theory of constraints (TOC) and wanted to iden- tify the bottleneck department. Which is it?

Answer 1

Order size =100

Shaping machines = S/U= 1 hour, run time = 1 min/piece

Pickling machine = one tank having a load of 200 units in each 4 hour

Packing= there are 4 individuals each having the production rate of 100/4 =25 units/hr

For shaping department =

Number of machines =3

S/U= 1 hr

RT = 1 min/piece

Time per batch =1+100/60 =2.67hr

Production =(100/2.67)*3 =112.5 piece/hr

For pickling department =

RT = 4hr/batch

Time per batch =4 hour

Production =200/4=50 piece/hr

For packing department =

Number of individuals =4

RT = 25 piece/hr/individual

Time per batch =1hr

Production =4*25=100 price hr

So the botleneck station of pickling department = with production rate of 50 piece/hr