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Production Capacity and Utilization Analysis

This document contains multiple questions regarding production machine capacity, utilization, availability, and manufacturing lead times. It provides information on production rates, shift schedules, downtimes, batch sizes, setup times, operation times, and more. It asks the reader to use this information to calculate capacities, utilization rates, expected outputs, manufacturing lead times, production rates, and work-in-process levels. The questions cover both single machine and full production line scenarios.

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niroshan24
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16 views1 page

Production Capacity and Utilization Analysis

This document contains multiple questions regarding production machine capacity, utilization, availability, and manufacturing lead times. It provides information on production rates, shift schedules, downtimes, batch sizes, setup times, operation times, and more. It asks the reader to use this information to calculate capacities, utilization rates, expected outputs, manufacturing lead times, production rates, and work-in-process levels. The questions cover both single machine and full production line scenarios.

Uploaded by

niroshan24
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOC, PDF, TXT or read online on Scribd

A production machine operates at 2 shifts/day and 5 days a week at full capacity.

Its production
rate is 20 unit/hr. During a certain week, the machine produced 1000 parts and was idle in the
remaining time, (a) Determine the production capacity of the machine, (b) What was the
utilization of the machine during the week under consideration? (c) If the availability of the
machine is 90%, and the utilization of the machines is 80%. Compute the expected plant output.

The mean time between failures for a certain production machine is 250 hours, and the mean
time to repair is 6 hours. Determine the availability of the machine.

One million units of a certain product are to be manufactured annually on dedicated production
machines that run 24 hours per day. 5 days per week, 50 weeks per year, (a) If the cycle time of
a machine to produce one part is 1.0 minute, how many of the dedicated machines will be
required to keep up with the demand? Assume that availability, utilization, and worker efficiency
= 100%, and that no setup time will be lost, (b) Solve part (a) except that availability = 0.90.

A certain part is produced in a batch size of 100 units. The batch must be routed through five
operations to complete the processing of the parts. Average setup time is 3 hr/operation, and
average operation time is 6 min. Average non operation time due to handling, delays,
inspections, etc., is 7 hours for each operation. Determine how many days it will take to
complete the batch, assuming the plant runs one 8-hr shift/day.

A certain part is routed through six machines in a


batch production plant. The setup and operation
times for each machine are given in the table below.
The batch size is 100 and the average non
operation time per machine is 12 hours. Determine
(a) manufacturing lead time and (b) production rate
for operation

A certain part is routed through six machines in a production


plant. The operation times for each machine are given in the
table below. Suppose the part is made in very large
quantities on a production line in which an automated work
handling system is used to transfer parts between machines.
Transfer time between stations = 15 s. The total time
required to set up the entire line is 150 hours. Assume that the operation times at the individual
machines remain the same. Determine (a) manufacturing lead time for a part coming off the
line.(b) production rate for operation 3. and (c) theoretical production rate for the entire
production line.
The average part produced in a certain batch manufacturing plant must be processed
sequentially through six machines on average. Twenty (20) new batches of parts are launched
each week. Average operation time = 6 minutes, average setup time = 5 hours, average batch
size= 25 parts, and average non operation time per batch = 10 hr/machine. There are 18
machines in the plant working in parallel. Each of the machines can be set up for any type of job
processed in the plant. The plant operates an average of 70 production hours per week. Scrap
rate is negligible. Determine (a) manufacturing lead time for an average part, (b) plant capacity,
and (c) plant utilization, (d) Determine the average level of work-in-process in the plant.

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