A manufacturing company produces a single product at four workstations in series (assume no variability). The company operates 3 shifts of 8 hrs per day, 5 days per week. Each shift contains one lunch break of 40 min. The processing time per unit as well as the number of machines per station is indicated in the table below. After every 500 units produced, the tools used in the machines at station 1 need to be replaced. It takes on average 30 minutes per machine to replace the tools. All the machines can process one unit at a time only, except for station 1 where each machine can process 5 units simultaneously.

(a) Which station is the bottleneck? Bottleneck station is station number: (b) What is the process capacity in units per day (round to the nearest integer)? x units per day (c) What is the cycle time of station 3 in minutes (give to 3 decimals)? min per unit (d) If this production system produced on average 50 units per day, what was the capacity utilisation at station 1 (round to nearest integer)? % (e) If this production system produced on average 60 units per day, how much spare capacity was available at station 4 (in \%, rounded to nearest integer)? %