Formtech Inc. produces transformers. Each order is custom designed and manufactured for the customer. Each order goes through 3 phases: Transformer Design, which takes 4 weeks. Procurement, which has a lead time of 8 weeks. Assembly and Testing, which takes 4 weeks The design group can handle only 4 projects at any given time. The other groups are not capacity constrained. How much total work-in-process (number of projects started but not yet completed) does the company typically have? (Hint: Little's Law)
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Formtech Inc. produces transformers. Each order is custom designed and manufactured for the customer. Each order goes through 3 phases:
- Transformer Design, which takes 4 weeks.
- Procurement, which has a lead time of 8 weeks.
- Assembly and Testing, which takes 4 weeks
The design group can handle only 4 projects at any given time. The other groups are not capacity constrained.
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- Sawing 20 min/unit Sanding 20 min/unit Drilling 32 min/unit Welding 30 min/unit Assembly 93 min/unit Assembly 93 min/unit Assembly 93 min/unit A production process is shown in the figure above. The drilling operation occurs separately from, and simultaneously with the sawing and sanding operations. Welding starts when both drilling and sanding operations have been completed. After welding, a product needs to go through only one of the three assembly operations (the operations are in parallel, where parallel lines perform the exact same operation). Considering the process times at stations, what is the process time of the system (in min/unit)?Assume that Product Z is made of two units of A and four units of B. A is made of three units of C and four of D. D is made of two units of E. B is made of three units of E. If 50 units of Z is required to make, then how many units of D do they need? Group of answer choices 250 400 300 150 550Radhika is a co-founder of a textile design firm worth 100 million. The firm started 5 years back with 3 founders- Radhika, Joy and Tara. Each founder now heads a separate department. Radhika heads the innovation and new design arm. Joy and Tara head manufacturing and finance departments respectively. Recently the departments are at loggerheads because of one big order that they lost. What shall Radhika do? Note: Make sure you select all of the correct options—there may be more than one! Discuss with external stakeholders to find the real cause, so as to tell Joy and Tara about the issue and make necessary corrections Discuss with Joy and Tara and understand why the order may have been lost. If there is something that can be done to harness cooperation among department, it shall be done Discuss with Joy and Tara to penalize the team that was responsible for this Discuss with Joy and Tara and understand not only why the order may have been lost, but how new orders may be created.…
- . Aquatica makes underwater camera housings for divers. The process begins with a solid rectangular block of aluminum that is used to make a single housing. A computer numerically controlled (CNC) machine drills into the block to make the metal “frame” of the housing. Each block requires 15 minutes of drilling. The frame is then chemically treated in a series of baths. There is ample capacity in the treating stage. Finally, a worker must manually attach the various buttons and components to the metal housing. This assembly takes 120 minutes per housing per worker and Aquatica has 6 workers trained to do this task. The CNC machine requires a 30-minute setup time before the production of a batch can begin. a. If the CNC machine produces 14 housings between setups, what would be its capacity (in housings per hour)? b. Assuming the process is supply-constrained, what is the utilization (as a number between 0 and 1) of the CNC machine if it operates in batches of 14 housings? c. Assuming…A production process at Kenneth Day Manufacturing is shown in the figure below. The drilling operation occurs separately from, and simultaneously with, the sawing and sanding, which are independent sequential operations. A product needs to go through only one of the three assembly operations (the operations are in parallel). 6 units/hr Sawing 2.5 units/hr Sanding Drilling 1.8 units/hr Welding 7 units/hr Assembly 0.7 units/hr Assembly 0.7 units/hr Assembly 0.7 units/hrLead Time Gourmet Helper Appliance Company manufactures home kitchen appliances. The manufacturing process includes stamping, final assembly, testing and shipping. In the stamping operation, a number of individuals are responsible for stamping the steel outer surface of the appliance. The stamping operation is set up prior to each run. A run of 75 stamping is completed after each setup. A setup requires 40 minutes the parts wait for the setup to be completed before stamping begins. Each stamping requires 5 minutes of operating time. After each batch is completed, the operator moves stamp the stamped covers to the final assembly area. This move takes 10 minutes to complete. The final assembly for each appliance unit requires 18 minutes and is also done in batches of 75 appliance units. The batch of 75 appliance units is moved into the test building, which is crossed street. The move takes 25 minutes. In the final test, the 75 unit batch is tested one at a time. Each test…
- A Company produces a component for use in the aerospace industry. The component consists of three parts (A, B and C), which are purchased externally and cost 50c, 60c and 70c per piece respectively. Parts A and B are assembled first on assembly line 1, which produces 150 components per hour. Part C undergoes a drilling operation before being finally assembled with the output from assembly line 1. There are six drilling machines in total, but only three are currently operational. Each drilling machine drills part C at a rate of 30 parts per hour. The final assembly line has a production capacity of 100 components per hour. At present, components are produced eight hours a day, five days a week. If the need arises, management can add a second shift of eight hours for the assembly lines only. The cost of assembly labour is 40c per assembly operation for each assembly line; the cost of drilling labour is 20c per part. For drilling, the cost of electricity is 10c per part. The overhead cost…A production process at Kenneth Day Manufacturing is shown in the figure below. The drilling operation occurs separately from, and simultaneously with, the sawing and sanding, which are independent sequential operations. A product needs to go through only one of the three assembly operations (the operations are in parallel). 7 units/hr 5 units/hr Assembly 0.8 units/hr Sawing Sanding Welding Assembly 2.1 units/hr 0.8 units/hr Drilling 2.5 units/hr Assembly 0.8 units/hr a) is the bottleneck. b) The bottleneck time is minutes per unit (round your response to two decimal places). c) The throughput time of the overall system is minutes (round your response to two decimal places).Suppose a final assembly is produced by assembling two components. THE The first component, A, is produced internally and goes through three process steps, which are stamping, forging and machining, with scrap estimates of 10%, 15% and 25%, respectively. For every three produced units of component A, two are used in the final assembly and one is separate to meet spare parts needs. The second component, B, which is used exclusively in final assembly, is purchased from a supplier external and inspected on arrival; 2% do not pass inspection. A unit of the component purchased is required for each final assembly. The final assembly process produces 5% of scraps. Spare parts demands for component A and final Su assembly match to 1,000 and 5,000 units, respectively. How many input units are needed for produce component A, and how many units of component B should the firm buy?
- Recall "Tommy's Dresses to go" case. Three years after, this company still rents designer dresses to customers, but it has managed to streamline its internal processes and expand to different segments of demand. Now, customers can rent clothes for anywhere between 1 days to 30 days, and each customer is sent only one (1) dress (instead of 2 dresses described in the case). The company alsó takes only 13 number of days to turn around a dress (i.e., this the duration starting with return from a customer, to again being rented out to a customer). The current demand is an average of 1,000 customers per day, and the company owns total of 30 thousand dresses. What is the average rental duration? (i.e., what is the average number of days, a customer keeps a dress).Which of the following statements about Just-in-time (JIT) and flexible production are false? Flexible production allows for complex products like the iPhone to be produced from raw materials in one industrial complex. Flexible production methods result in fewer models of a given product (cars, smart phones, etc.) than traditional manufacturing. Flexible production is designed to allow producers to shift quickly and easily between different levels of output. ✓ Just-in-time production was pioneered by Henry Ford.The Goodparts Company produces a component that is subsequently used in the aerospace industry. The component consists of three parts (A, B, and C) that are purchased from outside and cost 35, 30, and 10 cents per piece, respectively. Parts A and B are assembled first on assembly line 1, which produces 185 components per hour. Part C undergoes a drilling operation before being finally assembled with the output from assembly line 1. There are, in total, six drilling machines, but at present only three of them are operational. Each drilling machine drills part C at a rate of 80 parts per hour. In the final assembly, the output from assembly line 1 is assembled with the drilled part C. The final assembly line produces at a rate of 205 components per hour. At present, components are produced eight hours a day and five days a week. Management believes that if the need arises, it can add a second shift of eight hours for the assembly lines. The cost of assembly labor is 30 cents per part for…