A company wants to produce 1000 units per day, on average. It is considering implementing one of two processes, Process Alpha or Process Beta, for production. Both processes require three steps (i.e. three operations) to complete a unit. Look at Process Alpha below. Processing goes from a common Step 1 to a parallel Step 2A/2B and then back to a common Step 3.
Some of the managers thought that this was too complicated for the workers, so they designed a potential Process Beta as a substitute. In Process Beta, there are two separate production lines. In line A, Step 1A happens, then Step 2A, then Step 3A. In line B, Step 1B happens, then Step 2B, then Step 3B.
The output from Step 3A and Step 3B are the same. The 1000 units can come from any combination of Step 3A or Step 3B.
Alpha:
Step1: 250 units/hr
Step 2A: 100units/hr Step 2B: 150 units/hr
Step3: 300 units /hr
Beta:
Step 1A: 125 units/hr Step 1B: 125 units/hr
Step 2A: 100 units/hr Step 2B: 150 units/hr
Step 3A: 150 units/hr Step 3B: 150 units/hr
Answer the following questions:
A. Where is the bottleneck in Process Alpha?
B. What is the max capacity of Process Alpha?
C. Where is the bottleneck of Line A of Process Beta?
D. What is the max capacity of Line A of Process Beta?
E. Where is the bottleneck of Line B of Process Beta?
F. What is the max capacity of Line B of Process Beta?
G. What is the total max capacity of Process Beta (adding together the two lines)?
H. Using the flow time equation, how long will it take Process Alpha to produce 1000 units?
I. Using the flow time equation, how long will it take Process Beta to produce 1000 units?
J. Suppose the capacity assigned to Step 1A and Step 1B of Process Beta could be altered. By keeping the sum of the two capacities at 250 units/hour, how would you assign the capacity at Step 1A and Step 1B to maximize Process Beta’s max capacity? (for example, you could put 50 units/hour of capacity at Step 1A and 200 units/hour of capacity at Step B)