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The capacities of the Panel, ECAT, and Box plants are 1,000, 1,000, and 950 per day measured in PC equivalents (e.g., if a PC requires

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The capacities of the Panel, ECAT, and Box plants are 1,000, 1,000, and 950 per day measured in PC equivalents (e.g., if a PC requires two circuit boards, then a plant that produces 1,000 PC equivalents per day produces 2,000 circuit boards per day). Using current batch sizes and accounting for time to move parts from one plant to another, the raw process times (minimum average times for a batch to go through the plant and be delivered to the next plant) for the Panel, ECAT, and Box plants are 8 hours, 16 hours, and 12 hours. All three plants work 24 hours per day, 7 days per week. a. Suppose there is no yield loss at any of the plants. What are the bottleneck rate (BNR), raw process time (RPT), and critical WIP (CWIP) for this system? b. Now suppose that there is a 10 percent yield loss after ECAT. (That is, the last operation in the ECAT process is a test, which indicates 10 percent of the boards are defective.) How does this change the bottleneck rate (BNR)? If defective boards can go through the Panel and ECAT plants a second time (with the same process times as the first pass) and yield on the second pass is 100 percent, what is the raw process time (RPT)? (Hint: Remember that RPT is the average time for an entity to go through the flow with no waiting [queueing] time.) c. Compute the critical WIP (CWIP) for the line with yield loss. Why is this number higher than that for the line without yield loss

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