Question
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 |
- 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)
- What batch size would minimize inventory without decreasing the process capacity? (report your answer as an integer)
- What batch size would minimize inventory without decreasing the current flow rate? (report your answer as an integer)
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