3.A factory produces one product. One unit of raw material is required for each unit of product.
Two
processes are required to produce the product, process 1, which feeds into process 2. A totalof five
identical machines are available in the plant that can be set up to perform either process.Once set
up, each machine will be dedicated to perform that process. For each machine that is setup for
process 1, production rate = 12 units per hour. For each machine that is set up for process
2,production rate = 18 units per hour. Both processes produce 100% good units (fraction defect rate=
0). A work-in-process buffer is provided between the two processes to avoid starving andblocking of
machines. The factory operates 40 hours per week. (a) In order to maximize factoryproduction, how
many machines should be set up for process 1, and how many machines should beset up for process
2? (b) What is the factory’s maximum possible weekly production rate of goodproduct units?
3.3A factory produces cardboard boxes. The production sequence consists of three operations: (1)
cutting, (2) indenting, and (3) printing. There are three automated machines in the factory, one for each
operation. The machines are 100% reliable and the scrap rate in each operation is zero. In
the cutting operation, large rolls of cardboard are fed into the cutting machine, which cuts the
cardboard into blanks. Each large roll contains enough material for 4000 blanks. Production time = 0.03
min/blank during a production run, but it takes 25 min to change rolls and cutting dies between runs. In
the indenting operation, indentation lines are pressed into the printed blanks that allow the blanks to
later be bent into boxes. Indenting is performed at an average time of 2.5 sec. per blank. Batches from
the previous cutting operation are subdivided into two smaller batches with different indenting lines, so
that starting batch size in indenting = 2000 blanks. Time to change dies between batches on the
indenting machine = 30 min. In printing, the blanks are printed with labels for a particular customer.
Starting batch size in printing = 2000 blanks (these are the same batches as in indenting). Production
rate = 30 blanks/min. Between batches, changeover of the printing plates is required, which takes 40
min. What is the maximum possible output of this factory during a 40-hour week, in printed and
indented blanks/week. Assumptions: (i) steady state operation and (ii) there is work-in-process
between operations 1 and 2 and between 2 and 3, so that blocking and starving of operations is
negligible.
Five workstations (1, 2, 3, 4, and 5) that produce about ten similar parts must be arranged into an in-
line layout. The daily flow of parts between workstations is as follows: 40 parts from stations 5 to 2,
35 parts from stations 5 to 3, 20 parts from stations 3 to 1, 25 parts from stations 1 to 4, 60 parts
from 3 to 2, 15 parts from stations 2 to 5, and 30 parts from stations 4 to 2.
A) Use the Hollier algorithm described to determine the most logical sequence of stations in the work
system. B) Draw the network diagram for the system.C) Compute the percentage of in-sequence
moves, by-passing moves, and backflow moves for the sequence.
