Exam 5: Constraint Management

Table 5.7 The Terminal Company is attempting to balance its assembly line of high-voltage electrical connectors.The desired output for the line is 50 connectors per hour,and the information on the work elements for this assembly line is as follows. -Use the information from Table 5.7,and assume that the most efficient line balance possible has been achieved.What is the total idle time for an eight hour work day?

A bottleneck process has the lowest capacity and the longest total time from the start to the finish.

Every time a manufacturer uses one resource,they make a lot size of 300.Once a group of 30 units are completed,they are taken to the next step in the process.The lot of 300 is the ________ and the group of 30 is the ________.

Explain why a bottleneck limits system output.

The most controversial aspect of line-flow layout is:

What are five of the seven key principles of the Theory of Constraints?

Table 5.5 Balance the following line for an output rate of 3 units per minute. -Use the information in Table 5.5.How many stations are required?

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

Figure 5.1 The figure above shows the process for paying tuition at a major university.Students receive their bill,for the next term,for review.They are directed to different tables for clarifications,before being asked to pay their tuition at E.The numbers in parentheses are the time in minutes for each step of the process. -Use the information in Figure 5.1.What is the throughput time for the A-B-D-E process route?

Paced lines require that inventory storage areas be placed between stations.

Table 5.3 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 5.3.Which machine is the bottleneck operation?

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 traditional method,what is the optimal product mix?

Line balancing applies only to line processes that do assembly work,or to work that can be bundled in many ways to create the jobs for each workstation in the line.

A(n)________ line is a product line that produces several items belonging to the same family.

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 5.6 Balance the following line for an output rate of five pieces per hour.The times are in minutes (not seconds). -Use the information from Table 5.6.The highest efficiency for a balanced line is:

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

Fun Vehicles,Inc.makes beach buggies on an assembly line.The total productive time to make one buggy is 300 seconds.The current line has a 90-second cycle time and consists of four workstations.The balance delay of this line must be:

Figure 5.3 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 Figure 5.3.How many customers can be processed through the A-B-C-D-G routing during a 4-hour evening session?

The Theory of Constraints method is also referred to as the drum-buffer-rope method.