Exam 5: Constraint Management

A line balance that is 100% efficient must:

Table 5.2 A company makes four products that have the following characteristics: Product A sells for $75 but needs $20 of materials and $20 of labor to produce;Product B sells for $90 but needs $45 of materials and $20 of labor to produce;Product C sells for $110 but needs $50 of materials and $30 of labor to produce;Product D sells for $135 but needs $75 of materials and $40 of labor to produce.The processing requirements for each product on each of the four machines are shown in the table. Work centers W,X,Y,and Z are available for 40 hours per week and have no setup time when switching between products.Market demand is 50 As,60 Bs,70 Cs,and 80 Ds per week.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 5.2.Using the bottleneck method,what is the optimal product mix?

Table 5.4 The Superior Management Company assembles muffalettas in The Big Easy.The steps to making a world class sandwich and the time required (in seconds)for each step are shown in the table. -Customers demand muffalettas at the rate of 20 sandwiches per hour.Use the information in Table 5.4 to determine the maximum efficiency you can achieve balancing this line with an output rate that meets demand.

An assembly line has to perform 10 work elements,whose time requirements follow.An operations analyst has found a solution using some heuristics,as shown in the table.If the cycle time of the line is 90 seconds,what is the efficiency of the assembly line?

Table 5.1 A company makes four products that have the following characteristics: Product A sells for $50 but needs $10 of materials and $15 of labor to produce;Product B sells for $75 but needs $30 of materials and $15 of labor to produce;Product C sells for $100 but needs $50 of materials and $30 of labor to produce;Product D sells for $150 but needs $75 of materials and $40 of labor to produce.The processing requirements for each product on each of the four machines are shown in the table. Work centers W,X,Y,and Z are available for 40 hours per week and have no setup time when switching between products.Market demand for each product is 80 units per week.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 5.1.Using the bottleneck method,which product should be scheduled first?

What are two ways a process manager can identify a bottleneck in a service or manufacturing process? If you were in a manufacturing firm,what physical cues would signal a bottleneck?

Table 5.1 A company makes four products that have the following characteristics: Product A sells for $50 but needs $10 of materials and $15 of labor to produce;Product B sells for $75 but needs $30 of materials and $15 of labor to produce;Product C sells for $100 but needs $50 of materials and $30 of labor to produce;Product D sells for $150 but needs $75 of materials and $40 of labor to produce.The processing requirements for each product on each of the four machines are shown in the table. Work centers W,X,Y,and Z are available for 40 hours per week and have no setup time when switching between products.Market demand for each product is 80 units per week.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 5.1.Using the bottleneck method,what is the optimal product mix (consider variable costs only-overhead is not included in this profit calculation)?

Balance delay could be described as the:

Line balancing is the assignment of work to stations in a line to achieve the desired output rate with the smallest number of workstations.

Table 5.1 A company makes four products that have the following characteristics: Product A sells for $50 but needs $10 of materials and $15 of labor to produce;Product B sells for $75 but needs $30 of materials and $15 of labor to produce;Product C sells for $100 but needs $50 of materials and $30 of labor to produce;Product D sells for $150 but needs $75 of materials and $40 of labor to produce.The processing requirements for each product on each of the four machines are shown in the table. Work centers W,X,Y,and Z are available for 40 hours per week and have no setup time when switching between products.Market demand for each product is 80 units per week.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 5.1.Using the traditional method,which product should be scheduled first?

Regardless of the number of tasks or their lengths,a line balance efficiency of 100% is possible if the number of stations is ________.

The production of a particular product consists of the following work elements.If the cycle time is 4 minutes and the work-element times are as follows,what is the theoretical minimum number of stations?

Describe three ways that line balancing and line flow layouts are similar to project management and three ways that they are different from project management.

Schmidt Industries makes four different snake traps;the Harlan,the Gaylen,the Leah and the Matthew.The Harlan sells for $200 and has $40 in parts and $40 in labor;the Gaylen sells for $150 and requires $30 in parts and $30 in labor;the Leah sells for $100 and has $20 in parts and $20 in labor;and the Matthew sells for $75 but requires only $10 of parts and $10 of labor.Schmidt Industries has four machines (we'll call them A,B,C,and D for convenience)that are used in the production of each of these products.Each of these 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. Schmidt Industries has monthly fixed costs of $5000 and has a demand forecast of 80 Harlans,60 Gaylens,40 Leahs and 20 Matthews for the coming month.How many of each of the four models should Susan,the operations manager,schedule for production this month?

Consider the following production process.It is trying to meet a market demand of 500 units per week. Step 1: Material release schedule Step 2: Drilling (capacity is 500 units/week) Step 3: Tapping (capacity is 450 units/week) Step 4: Grinding (capacity is 600 units/week) Step 5: Coating (capacity is 400 units/week) Step 6: Inspection (capacity is 1000 units/week) a.Where should buffers be placed? b.Which resource is the drum? c.Where should the rope be placed? d.Which resource is the bottleneck? e.Which resource is the CCR?

What is the definition of "theoretical maximum efficiency"?

In a drum-buffer-rope system,the lot size that moves from one work center to another for additional processing is a(n):

Which of the following statements concerning line balancing is TRUE?

Short term capacity planning should be driven by identification and management of bottlenecks.

Variability of a firm's workload may create ________.