Abbott Manufacturing produces plastic cases for solar photovoltaic panels and has decided to combine orders from customers to increase work order size, and thereby, make one large production run per model type. Plastic injection molding machines are used to make these parts and it is time consuming to clean and re-setup the machines between production runs. Each molding machine and operator works one nine-hour shift with a one-hour lunch break and one-half hour for operator breaks.

What is the total workload (demand) in hours for this work order mix? How many machines will it take to do this work in one, two or three days? How might this process be improved?

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Consolidated Work Work Order Setup (Changeover) Processing Time Time per Work Order (minutes) 90 75 150 Orders Quantity Model XVT-5 Case 9,500 panels Model UYT-3 Case Model KLY-6 Case per Panel (seconds) 2.05 1.78 4.31 7,500 10,800