Exam 7: Constraint Management

Table 7.4 The figure above shows the process for customers arriving at Hobbies Unlimited for several advertised crafts demonstrations.After signing in,customers are routed to different locations in the store for the two different programs provided.The numbers in parentheses are the time in minutes for each step of the process. -Use the information in Table 7.4.What is the throughput time for the A-B-C-D-G routing?

Given the following data about an assembly line and the knowledge that we are trying to attain an output rate of 40 units per hour,what is the theoretical minimum number of stations?

Table 7.6 Burdell Industries makes four different models of computer printers: the E-1000,the S-2000,the P-2000 and the N-1000.The E-1000 sells for $200 and has $40 in parts and $40 in labor;the S-2000 sells for $150 and requires $30 in parts and $30 in labor;the P-2000 sells for $100 and has $20 in parts and $20 in labor;and the N-1000 sells for $75 but requires only $10 of parts and $10 of labor.Fixed overhead is estimated at $5,000 per week.The manufacture of each printer requires four machines,Machines #1,2,3 and 4.Each of the machines is available for 40 hours a week and there is no setup time required when shifting from the production of one product to any other.The processing requirements to make one unit of each product are shown in the table.Weekly product demand for the next planning period has been forecasted as follows: 80 E-1000s;65 S-2000s;35 P-2000s;and 20 N-1000s. In the questions that follow,the traditional method refers to maximizing the contribution margin per unit for each product,and the bottleneck method refers to maximizing the contribution margin per minute at the bottleneck for each product. -Use the information in Table 7.6.Using the traditional method,what is the optimal product mix?

________ is a planning and control system that regulates the flow of work-in-process materials at the bottleneck or the capacity constrained resource in a productive system.

Consider consecutive processes A-B-C,where process A has a capacity of 20 units per hour,process B has a capacity of 25 units per hour,and process C has a capacity of 30 units per hour.Where would an operations manager want any inventory?

Balance the assembly line for the tasks contained in the table.The desired output is three units per hour.Available production time per day is eight hours.What is the theoretical minimum number of stations? What is the efficiency for the balanced assembly line?

Table 7.1 The figure above shows the call routing process for a customer service call center.Incoming calls are routed,depending on the complexity of the caller's request.Simple request are routed to work center B,while the more complex calls are routed to work center C (which also takes simple calls when not busy).The numbers in parentheses are the time in minutes for each step of the process. -Use the information in Table 7.1.Where would you expect customer wait times to occur?

Table 7.9 Balance the following line for an output rate of 3 units per minute. -Use the information in Table 7.9.How many stations are required?

________ is the maximum rate of output of a process or a system.

Work should be released into the system when:

Use the process flow diagram to determine which of these events has the greatest net benefit.

Table 7.8 King Supply makes four different types of plumbing fixtures: W,X,Y and Z.The contribution margins for these products are: $70 for Product W,$60 for Product X,$90 for Product Y and $100 for Product Z.Fixed overhead is estimated at $5,500 per week.The manufacture of each fixture requires four machines,Machines #1,2,3 and 4.Each of the machines is available for 40 hours a week and there is no setup time required when shifting from the production of one product to any other.The processing requirements to make one unit of each product are shown in the table.Weekly product demand for the next planning period has been forecasted as follows: 70 Ws,60 Xs,50 Ys and 30 Zs. In the questions that follow,the traditional method refers to maximizing the contribution margin per unit for each product,and the bottleneck method refers to maximizing the contribution margin per minute at the bottleneck for each product. -Use the information in Table 7.8.Using the bottleneck method,in what sequence should products be scheduled for production?

Table 7.6 Burdell Industries makes four different models of computer printers: the E-1000,the S-2000,the P-2000 and the N-1000.The E-1000 sells for $200 and has $40 in parts and $40 in labor;the S-2000 sells for $150 and requires $30 in parts and $30 in labor;the P-2000 sells for $100 and has $20 in parts and $20 in labor;and the N-1000 sells for $75 but requires only $10 of parts and $10 of labor.Fixed overhead is estimated at $5,000 per week.The manufacture of each printer requires four machines,Machines #1,2,3 and 4.Each of the machines is available for 40 hours a week and there is no setup time required when shifting from the production of one product to any other.The processing requirements to make one unit of each product are shown in the table.Weekly product demand for the next planning period has been forecasted as follows: 80 E-1000s;65 S-2000s;35 P-2000s;and 20 N-1000s. In the questions that follow,the traditional method refers to maximizing the contribution margin per unit for each product,and the bottleneck method refers to maximizing the contribution margin per minute at the bottleneck for each product. -Use the information in Table 7.6.Using the traditional method,what is the profit if Burdell manufactures the optimal product mix?

Table 7.3 The figure above shows the process for customers arriving at Pierre's Spa and Salon.After signing in,customers are routed to different locations in the Spa for the two different services provided.The numbers in parentheses are the time in minutes for each step of the process. -Use the information in Table 7.3.What is the throughput time for the A-B-C-D -H routing?

A competent operations manager should first eliminate all of the bottlenecks from the process.

Table 7.4 The figure above shows the process for customers arriving at Hobbies Unlimited for several advertised crafts demonstrations.After signing in,customers are routed to different locations in the store for the two different programs provided.The numbers in parentheses are the time in minutes for each step of the process. -Use the information in Table 7.4.What is the throughput time for the A-B-E-F-G routing?

Table 7.8 King Supply makes four different types of plumbing fixtures: W,X,Y and Z.The contribution margins for these products are: $70 for Product W,$60 for Product X,$90 for Product Y and $100 for Product Z.Fixed overhead is estimated at $5,500 per week.The manufacture of each fixture requires four machines,Machines #1,2,3 and 4.Each of the machines is available for 40 hours a week and there is no setup time required when shifting from the production of one product to any other.The processing requirements to make one unit of each product are shown in the table.Weekly product demand for the next planning period has been forecasted as follows: 70 Ws,60 Xs,50 Ys and 30 Zs. In the questions that follow,the traditional method refers to maximizing the contribution margin per unit for each product,and the bottleneck method refers to maximizing the contribution margin per minute at the bottleneck for each product. -Use the information in Table 7.8.Which machine is the bottleneck operation?

Table 7.6 Burdell Industries makes four different models of computer printers: the E-1000,the S-2000,the P-2000 and the N-1000.The E-1000 sells for $200 and has $40 in parts and $40 in labor;the S-2000 sells for $150 and requires $30 in parts and $30 in labor;the P-2000 sells for $100 and has $20 in parts and $20 in labor;and the N-1000 sells for $75 but requires only $10 of parts and $10 of labor.Fixed overhead is estimated at $5,000 per week.The manufacture of each printer requires four machines,Machines #1,2,3 and 4.Each of the machines is available for 40 hours a week and there is no setup time required when shifting from the production of one product to any other.The processing requirements to make one unit of each product are shown in the table.Weekly product demand for the next planning period has been forecasted as follows: 80 E-1000s;65 S-2000s;35 P-2000s;and 20 N-1000s. In the questions that follow,the traditional method refers to maximizing the contribution margin per unit for each product,and the bottleneck method refers to maximizing the contribution margin per minute at the bottleneck for each product. -Use the information in Table 7.6.Which machine is the bottleneck operation?

In a shop managed according to TOC principles,inventory is needed only in front of bottlenecks in order to prevent them from sitting idle.

________ is the amount by which efficiency falls short of 100 percent.