PLEASE ANSWER (a) through (i)
D E E F B 4.5 4 3.5 6 4 00 0 5 4 O O 6 O 00 6 9 240 360 270 2160 180 1440 210 1680 1920 2880 150 0 90 0 0 0 0 120 600 0 150 90 90 120 120 0 750 450 450 480 600 930 1800 43.06% 125.00% 2 Number pf workers 3 Processing time for A (minutes/unit/worker) 4 Processing time for B (minutes/unit/worker) 5 Processing time for C(minutes/unit/worker) 6 Capacity 7 Capacity (minutes/hr) 8 Capacity (minutes/day) 9 Demand, Workload, & Implied Utilization 70 Demand for A (units/ day) 11 Demand for B (units/ day) 12 Demand for C(units/ day) 13 Workload on A (minutes/day) 74 Workload on B (minutes/day) 15 Workload on C(minutes/day) 16 Total workload (minutes/day) 17 Implied utilization 18 Flow rate & Utilization 19 Flow rate of A (units/day) 20 Flow rate of B (units/day) 21 Flow rate of C(units/day) 22 Effective workload on A (minutes/day) 23 Effective workload on B (minutes/day) 24 Effective workload on C(minutes/day) 25 Total effective workload (minutes/day) 26 Effective IU 27 Utilization 150 90 120 1200 540 1080 2820 97.92% 0 0 540 28.13% 960 1560 92.86% 120 120 72 72 96 96 0 600 360 360 384 480 744 1440 34.44% 100.00% 34.44% 100.00% 120 72 96 0 432 0 432 120 72 96 480 0 768 1248 74.29% 74.29% 120 72 96 960 432 864 2256 78.33% 78.33% 22.50% 22.50% 4 3 5 6 8 0 0 4 4 5 0 8 9 QUESTION 24 (10 points) - Process Analysis with Multiple Flow-Unit Types A process is composed of five resources working on products A, B, and C for eight hours a day. The table below summarizes the situation. You would need to choose a minute of work as the common flow unit for all products and resources. In addition, you need to explain and show your calculations steps. Some cells are prefilled for your reference. Use 2 decimal places. Resource & Process 1 2 3 4 5 Number of workers 4.5 3.5 Processing time for A (minutes/unit/worker) Processing time for B (minutes/unit/worker) 5 5 6 0 6 Processing time for C(minutes/unit/worker) Capacity Capacity (minutes/hour) Capacity (minutes/day) (8 hours/day) Demand, Workload, & Implied Utilization Demand for A (units/day) Demand for B (units/day) Demand for C (units/day) Workload on A (minutes/day) Workload on B (minutes/day) Workload on C (minutes/day) Total workload (minutes/day) 540 Implied utilization (%, 2 decimals) Flow Rate & Utilization Flow rate of A (units/day) Flow rate of B (units/day) Flow rate of C(units/day) Effective workload on A (minutes/day) Effective workload on B (minutes/day) Effective workload on C(minutes/day) Total effective workload (minutes/day) Effective IU (%, 2 decimals) 74.29% Utilization (%, 2 decimals) Note: if a worker works in multiple resources, the worker distributes his/her work time on those resources. In that case, the worker counts for the resources can be decimal numbers. On the supply side, we know how many workers are in charge of each resource and the processing time in minutes per unit for each product at each resource. Zero processing time means the product of interest does not go through the corresponding resource at all. Besides, assume that inputs are always sufficient. On the demand side, we know demands for products A, B, and C per day as follows: demand for A is 150 units per day; demand for B is 90 units per day; and demand for Cis 120 units per day. We assume a fixed product mix of A:B:C = 5:3:4. (a)[2] Draw a process flow diagram of the process, assuming that there are buffers between resources. Make sure to have process boundaries. (b)[1] Find two measures of capacity for each resource as in the table. (c)[1] Find total workload on each resource. (d) [1] Find implied utilizations of individual resources. Draw the implied utilization profile. (e) [1] Find the bottleneck and the demand-acceptance ratio (if IU[BN] > 1 then DAR = 1/10[BN]). (f)[1] Based on the demand-acceptance ratio, find the effective flow rates of A, B, and C. Explain. (e)[1] Find total effective workload and effective IU on each resource. (h)[1] Find utilizations of individual resources. Draw the utilization profile. (0)[1] Process analysis is for designing and improving business processes! By looking at the implied utilization and utilization profiles, propose one way to reallocate workers among the resources so as to increase the flow rates of products A, B, and C. For this part, you should try to implement the table in Excel and reallocate workers in your Excel template. D E E F B 4.5 4 3.5 6 4 00 0 5 4 O O 6 O 00 6 9 240 360 270 2160 180 1440 210 1680 1920 2880 150 0 90 0 0 0 0 120 600 0 150 90 90 120 120 0 750 450 450 480 600 930 1800 43.06% 125.00% 2 Number pf workers 3 Processing time for A (minutes/unit/worker) 4 Processing time for B (minutes/unit/worker) 5 Processing time for C(minutes/unit/worker) 6 Capacity 7 Capacity (minutes/hr) 8 Capacity (minutes/day) 9 Demand, Workload, & Implied Utilization 70 Demand for A (units/ day) 11 Demand for B (units/ day) 12 Demand for C(units/ day) 13 Workload on A (minutes/day) 74 Workload on B (minutes/day) 15 Workload on C(minutes/day) 16 Total workload (minutes/day) 17 Implied utilization 18 Flow rate & Utilization 19 Flow rate of A (units/day) 20 Flow rate of B (units/day) 21 Flow rate of C(units/day) 22 Effective workload on A (minutes/day) 23 Effective workload on B (minutes/day) 24 Effective workload on C(minutes/day) 25 Total effective workload (minutes/day) 26 Effective IU 27 Utilization 150 90 120 1200 540 1080 2820 97.92% 0 0 540 28.13% 960 1560 92.86% 120 120 72 72 96 96 0 600 360 360 384 480 744 1440 34.44% 100.00% 34.44% 100.00% 120 72 96 0 432 0 432 120 72 96 480 0 768 1248 74.29% 74.29% 120 72 96 960 432 864 2256 78.33% 78.33% 22.50% 22.50% 4 3 5 6 8 0 0 4 4 5 0 8 9 QUESTION 24 (10 points) - Process Analysis with Multiple Flow-Unit Types A process is composed of five resources working on products A, B, and C for eight hours a day. The table below summarizes the situation. You would need to choose a minute of work as the common flow unit for all products and resources. In addition, you need to explain and show your calculations steps. Some cells are prefilled for your reference. Use 2 decimal places. Resource & Process 1 2 3 4 5 Number of workers 4.5 3.5 Processing time for A (minutes/unit/worker) Processing time for B (minutes/unit/worker) 5 5 6 0 6 Processing time for C(minutes/unit/worker) Capacity Capacity (minutes/hour) Capacity (minutes/day) (8 hours/day) Demand, Workload, & Implied Utilization Demand for A (units/day) Demand for B (units/day) Demand for C (units/day) Workload on A (minutes/day) Workload on B (minutes/day) Workload on C (minutes/day) Total workload (minutes/day) 540 Implied utilization (%, 2 decimals) Flow Rate & Utilization Flow rate of A (units/day) Flow rate of B (units/day) Flow rate of C(units/day) Effective workload on A (minutes/day) Effective workload on B (minutes/day) Effective workload on C(minutes/day) Total effective workload (minutes/day) Effective IU (%, 2 decimals) 74.29% Utilization (%, 2 decimals) Note: if a worker works in multiple resources, the worker distributes his/her work time on those resources. In that case, the worker counts for the resources can be decimal numbers. On the supply side, we know how many workers are in charge of each resource and the processing time in minutes per unit for each product at each resource. Zero processing time means the product of interest does not go through the corresponding resource at all. Besides, assume that inputs are always sufficient. On the demand side, we know demands for products A, B, and C per day as follows: demand for A is 150 units per day; demand for B is 90 units per day; and demand for Cis 120 units per day. We assume a fixed product mix of A:B:C = 5:3:4. (a)[2] Draw a process flow diagram of the process, assuming that there are buffers between resources. Make sure to have process boundaries. (b)[1] Find two measures of capacity for each resource as in the table. (c)[1] Find total workload on each resource. (d) [1] Find implied utilizations of individual resources. Draw the implied utilization profile. (e) [1] Find the bottleneck and the demand-acceptance ratio (if IU[BN] > 1 then DAR = 1/10[BN]). (f)[1] Based on the demand-acceptance ratio, find the effective flow rates of A, B, and C. Explain. (e)[1] Find total effective workload and effective IU on each resource. (h)[1] Find utilizations of individual resources. Draw the utilization profile. (0)[1] Process analysis is for designing and improving business processes! By looking at the implied utilization and utilization profiles, propose one way to reallocate workers among the resources so as to increase the flow rates of products A, B, and C. For this part, you should try to implement the table in Excel and reallocate workers in your Excel template
