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Assignment 1 On Process Analysis

The document describes 4 assignment questions about production processes and bottlenecks. Question 1 involves analyzing cycle times and throughput rates. Question 2 involves identifying the bottleneck in Netflix's development process. Question 3 describes a toy bicycle assembly line and asks questions about its bottleneck, capacity, utilization, and labor costs. Question 4 provides processing times and demands for 3 products across 5 resources to identify its bottleneck.

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Sourin Sau
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120 views8 pages

Assignment 1 On Process Analysis

The document describes 4 assignment questions about production processes and bottlenecks. Question 1 involves analyzing cycle times and throughput rates. Question 2 involves identifying the bottleneck in Netflix's development process. Question 3 describes a toy bicycle assembly line and asks questions about its bottleneck, capacity, utilization, and labor costs. Question 4 provides processing times and demands for 3 products across 5 resources to identify its bottleneck.

Uploaded by

Sourin Sau
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© © All Rights Reserved
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Download as PDF, TXT or read online on Scribd
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Assignment-1

Deadline: 25th October,2019


Question 1: From the link given below answer
the following questions
• http://dm.darden.virginia.edu/whichtime/

• Time markers above a customer (product) represent the accumulating


throughput time

• Time in the upper right corner represents the accumulating cycle time
of the customer (product) in the service
1. As the cycle time increases, what happened to the throughput time and
throughput rate? Why?
2. As the cycle time decreases, what happened to the throughput time and
throughput rate? Why?
3. As the line length increases, what happened to the throughput time and
throughput rate? Why?
4. As the line length decreases, what happened to the throughput time and
throughput rate? Why?
5. How does the minimum takt time that the system can handle change as the
cycle time changes?
6. How does the minimum takt time that the system can handle change as the line
length changes?
7. Is it possible for a process to have the same throughput rate with both high work
in process (WIP) and high throughput time and with low WIP and low
throughput time? Which would you rather have? Why?
Q2: Selection for Netflix Platform: Where is the Bottleneck?

500 70/500 20/70 6/20 2/6


NEW
PITCHES SCRIPTS PILOTS SHOWS
SERIES

• Input: 500 ideas per year

• Processing time and Resources (250 days /year) respectively


• Pitches: 2 days and 5 judges
• Scripts: 10 days and 3 script writers
• Pilots: 30 days and 2 pilot teams
• Shows: 70 days and 2 series crews
• New series: 200 days and 1 main crew
Q3. Atlas Inc. is a toy bicycle manufacturing company producing a five-inch small version of the
bike that Lance Armstrong rode to win his first Tour de France. The assembly line at Atlas Inc.
consists of seven work stations, each performing a single step. Stations and processing times
are summarized here:
• Step 1 (30 sec.): The plastic tube for the frame is cut to size.
• Step 2 (20 sec.): The tube is put together.
• Step 3 (35 sec.): The frame is glued together.
• Step 4 (25 sec.): The frame is cleaned.
• Step 5 (30 sec.): Paint is sprayed onto the frame.
• Step 6 (45 sec.): Wheels are assembled.
• Step 7 (40 sec.): All other parts are assembled to the frame.

Under the current process layout, workers are allocated to the stations as shown here:
• Worker 1: Steps 1, 2
• Worker 2: Steps 3, 4
• Worker 3: Step 5
• Worker 4: Step 6
• Worker 5: Step 7
• What is the bottleneck in this process?
• What is the capacity of this assembly line, in finished units/hour?
• What is the utilization of Worker 4, ignoring the production of the
first and last units?
• What is the average labor utilization of the workers, ignoring the
production of the first and last units?
• Assume the workers are paid $15 per hour. What is the cost of direct
labor for the bicycle?
Q 4: Consider a process consisting of five resources that are operated
eight hours per day. The process works on three different products, A,
B, and C:

Resource Number of Processing Processing Processing


workers time for A time for B time for C
(minutes) (minutes) (minutes)
1 2 5 5 5
2 2 4 4 5
3 1 12 0 0
4 1 0 3 3
5 2 6 6 4
• Demand for the three different products is as follows:
• product A, 40 units per day;
• product B, 50 units per day; and
• product C, 60 units per day.

• What is the bottleneck?

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