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3) Answer the following questions on Theory of constraints (Bottlenecks) Houston Industries Limited (HIL) produces a mix of affordable products (A, B, C) that
3) Answer the following questions on "Theory of constraints" (Bottlenecks) Houston Industries Limited (HIL) produces a mix of affordable products (A, B, C) that are fabricated and assembled in four different stations (W, X, Y, Z) although not necessarily in the same order. A flowchart of the manufacturing process is shown below with the information about the products (selling price, weekly demand, costs of raw materials and parts and production times) and the process sequence along the machining sites are listed below figure shown. Product A Step 2 Product Sep 1 Product C Step 2 Purchased part Product A The raw materials and purchasing parts are represented by the inverted triangles. YPI can sell all made guitars up to and including the weekly demand and does not have to pay fines if these quantities are not met. Each workstation is staffed by a specialized employee who only work alone and is paid $15 per hour. YPI operates 8 production hours per day during a 5-day working week with no overtime. Overhead costs are $9000 per week. a) Which workstation has the highest aggregate workload (and acts as a bottleneck) when they want to meet total demand for the next week? Based on the results in (a), we have to choose our production schedule carefully. Currently, production decisions are made using the traditional method, which is to accept as much products of the highest contribution margin (= sales price-cost of raw materials & purchased parts) up to the limit of its demand, followed by the next highest contribution margin, and so on until we meet a capacity limit b. Calculate the resulting production plan for next month using this method together with the overall costs and profits.
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