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A toy company currently operates for 48 hours per week and sells an average of 9,600 toys per week. The manufacturing process consists of three

A toy company currently operates for 48 hours per week and sells an average of 9,600 toys per week. The manufacturing process consists of three basic operations: molding, painting, and finishing (performed in that order). Changing over between different versions of toys requires setup time for painting and finishing. The table below lists the setup times for a batch and the processing times for each unit at each step. There is unlimited buffer space between these steps. Assume that:

  • Setups need to be completed first
  • A setup can only start once the batch has arrived at the resource
  • All flow units of a batch need to be processed at the resource before any of the units of the batch can be moved to the next resource.

Process Step

Molding

Painting

Finishing

Setup Time (mins)

No setup 25 20

Processing Time (mins/unit)

0.20 0.10 0.12

  1. What is the process capacity in units per hour with a batch size of 500 toys? (report your answer as toys/per hour as an integer)
  2. What batch size would minimize inventory without decreasing the process capacity? (report your answer as an integer)
  3. What batch size would minimize inventory without decreasing the current flow rate? (report your answer as an integer)

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