Question

Angels Inc. fabricates garage doors. Roofs are punched in a roof punching press (R-Punch) for 8 minutes per roof, and then are formed in a roof forming press (R-Form) for 15 minutes per roof. Bases are punched in a base punching press (B-Punch) for 13 minutes per base, and then formed in a base forming press (B-Form) for 11 minutes per base. The formed base is welded in a base welding machine (Weld) for 8 minutes per base. The base and the roof then go to final assembly (Assembly) which takes 12 minutes per garage door. There is one operator and one machine at each station. The operator and the machine work as a single server. Cap-B1.png 1. What is the Theoretical Flow Time? (The minimum time required to produce a garage door from start to finish.) The potential answers are: A: 44 minutes. B: 35 minutes. C: 61 minutes. D: 34 minutes. E: 28 minutes. B 2. What is the capacity of the factory, in terms of garage doors per hour? The potential answers are: A: 3.33 units. B: 3.16 units. C: 3 units. D: 6.67 units. E: 4 units. E 3. Where is the bottleneck? The potential answers are: A: B-Form B: Assembly C: R-Form D: R-Punch E: B-Punch C 4. Suppose we double the capacity of the bottleneck(s) by adding the same capital and human resources to each bottleneck. What is the new capacity of the system in terms of garage doors per hour? The potential answers are: A: 3.16 units. B: 4.62 units. C: 3.53 units. D: 3.33 units. E: 8.57 units. E 5. Where is the new bottleneck? The potential answers are: A: B-Punch B: R-Form C: B-Form D: Weld E: R-Punch

Answer 1

1. Time taken in preparing the roof =8+15 =23 min

Time taken in preparing the base =13+11 =24 min.

Tima taken in welding = 8 min

Total time taken with base = 24+8 =32 min.

Total time taken in the process = Max [ 23,32]+12 =32+12 =44 min

Option A is right.

2. Capacity of the base making will be determined by the slowest station i.e. pnching which has a capacity of 60/13 = 4.61 per hour

Capacity of the roof making process is determined by the slowest process i.e. roof punching which has a capacity of 60/15 =4 per hour.

number of parts reaching at assembly stage = 4 roofs and 4.61 bases.

Capacity of the assembly station = 60/12 =5 per hour.

SInce one unit of both base and roof is needed, the max capacity of assembly process will be 4 units per hour. Option E is right.

3. Bottleneck is roof punching process. d is right.

4. If more capacity is added to the bottleneck, the new bottleneck will be the base punching process with an output of 4.61, and the new capacity will be 4.61. Option B is right