1.
Problem: A plant has a designed capacity of 500 units per day, but it is currently
producing 400 units per day. What is the plant capacity utilisation rate?
2. Problem: A plant has a designed capacity of 1,000 units per week. Due to
maintenance, breakdowns, and setup time, 20% of the time is lost. What is the
effective capacity?
3. Problem: A plant's fixed costs are ₹5,00,000, variable cost per unit is ₹50, and
the selling price per unit is ₹100. What is the break-even production capacity?
4. Problem: A machine has a scheduled operating time of 10 hours per day, but
due to breakdowns and idle time, it operates for only 7 hours per day. What is the
machine utilisation rate?
5. Problem: A factory has 5 identical machines, each capable of producing 100
units per hour. If the machines run for 8 hours per day, what is the daily
production capacity?
6. Problem: A worker produces 40 units per hour during an 8-hour shift. If the
target is 350 units per day, is the worker meeting the target?
7. Problem: A plant produces 1,200 units in an 8-hour shift. The theoretical
maximum production rate is 200 units per hour. Calculate the productivity and
suggest improvements if the efficiency is below 85%.
8. Problem: A plant uses 5 machines, each consuming 15 kW. They operate for
10 hours daily at an energy cost of ₹6 per kWh. Calculate the monthly energy
cost.
9. Problem: A machine operates for 8 hours per day, but downtime accounts for
2 hours daily. Calculate the utilisation rate and suggest improvements if
utilisation is below 80%.
10. Problem: A plant with 3 machines, each producing 50 units per hour, operates
for 12 hours daily. If demand increases to 2,500 units per day, will the plant meet
the demand?
11. Problem: A plant has 4 machines, each capable of producing 80 units per
hour. The machines operate for 10 hours daily, but due to breakdowns, the actual
production is only 2,800 units daily. Calculate the capacity utilisation of the plant.
12. Problem: A factory needs to produce 12,000 units in a month. Each worker
can produce 20 units/day, and the plant operates 25 days a month. How many
workers are required to meet the target?
13. Problem: A plant currently produces 10,000 units/month with a capacity
utilisation of 80%. The demand is projected to increase to 15,000 units/month.
Calculate the percentage increase in capacity required to meet the projected
demand.
14. Problem: A factory operates a single 8-hour shift, producing 1,200 units/day.
Demand increases to 3,600 units/day. If adding shifts increases efficiency to 95%
per shift, how many shifts are required to meet the demand?
15. Problem: A plant produces 400 units per day in an 8-hour shift. The daily
demand increases to 500 units. If the plant operates overtime at the same rate,
how many extra hours are required daily to meet the demand?
16. Problem: A factory operates 2 shifts of 8 hours each with a total production
of 4,800 units per day. The theoretical maximum capacity is 3,000 units per shift.
Calculate the capacity utilisation for the factory.
17. Problem: A company currently employs 50 workers, each producing 25
units/day. Due to demand changes, the production target is increased to 1,500
units/day. How many additional workers are required to meet the new demand?
18. Problem: A machine has a design capacity of 200 units/hour, but due to
maintenance and minor stoppages, the effective capacity is reduced by 15%.
Calculate the effective capacity per hour and for an 8-hour shift.
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