Square Windows Case Study

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Square Windows Answer: (i) In order to identify the bottleneck, we must calculate the capacity of each of the three operations. When setup times are involved, it is useful to perform these calculations in terms of a product batch, rather than individual items. A batch consists of 360 units of part A and 720 units of part B. This will enable you to produce 360 units of finished products. Stamping: Time to complete a batch = 120 minutes/batch setup for part A + 360 pieces/batch x (1 minutes/unit of A) + 120 minute/batch setup for part B + 720 pieces/batch x (0.5 minute/unit of B) = 960 minutes = 2 days Therefore, daily capacity = 360 / 2 days = 180 units/day. Painting: Time to complete a batch = 20 minute/batch setup + 360 pieces x (0.5 minute/unit of A) + 720 pieces ( 1/6 minute/unit of B) = 320 minutes = 0.667 days. There paint capacity = 360 product units/0.667 days = 540 product units/day Assembly: Since assembly is labor paced, we must compare the labor content needed to make one finished unit against the total number of labour hours available per day. Labour content per day = 27 minute /product Total labour available per day = 12 workers x 60 minutes/hr x 8 hours/day Daily capacity = 5760 minutes/ (27 minute/finished unit) = 213 units of finished product/day Hence the bottleneck is at the stamping since it has the least capacity. Therefore, the total system can’t produce more than 180 finished units/day. It is sometimes suggested that we could increase the capacity of stamping, and therefore the entire process, if we reversed the sequence of A and B in successive runs, e.g., in first batch produce in order A, B, in the second batch B, A, then A, B, etc. This is an interesting idea and saves one setup per batch, but one might argue that really we’ve just doubled the effective batch size. We don’t need to consider the 2 hours dry

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