CBF, Inc. CBF is a small manufacturer who makes circuit boards. They are having a throughput problem. They need to complete 1000 boards/shift. They produce boards in batches. The desired batch throughput is 60 boards, but they currently start with a batch of 75 boards and lose 15% in the Inspection step and 5% in Final Test.

The basic data is 1000 boards required per 7.5 hour shift (.5hr is lost to breaks) working 5 days a week. The process step data is shown in the table below:

Process Step	# Machines	# Employees	Setup (minutes)	Run (mins/batch)
Load	1	1	5	3.33
Clean	1			1.5
Coat	1			2.5
Unload	1	1		3.50
Expose	5	5	15(each machine)	3.72
Load	1	1	5	5.33
Develop	1			2.33
Inspect	2	2		7.5
Bake	1			1.5
Unload	1	1		3.3
Drilling	6	3	15(each machine)	7.5
Plating	1	2	5	3.25
Final Test	6	6	15(each machine)	6.00

Currently the process is completing 700 boards per day. The first 4 steps use one machine. The next batch can start when the current batch completes. Steps 6-10 also use a single machine. Inspection is done with the boards loaded in that machine. Each of the other steps uses its own machine(s). Each machine can start the next batch when the current batch completes.

a. What is the maximum capacity of the process?

b. What is the impact of losses in Inspection and Final test?

c. Where is the bottleneck?

d. What do you recommend as a short term solution to the capacity problem?

e. What long term recommendations would you make?