Consider the following batch flow process consisting of three process steps performed by three machines:

Work is processed in batches at each step. Before a batch is processed at step 1, the machine has to be set up. During a setup, the machine is unable to process any product.
a. Assume that the batch size is 50 parts. What is the capacity of the process?
b. For a batch size of 10 parts, which step is the bottleneck for the process?
c. Using the current production batch size of 50 parts, how long would it take to produce 20 parts starting with an empty system? Assume that the units in the batch have to stay together (no smaller transfer batches allowed) when transferred to step 2 and to step 3. A unit can leave the system the moment it is completed at step 3. Assume step 1 needs to be set up before the beginning of production.
d. Using the current production batch size of 50 parts, how long would it take to produce 20 parts starting with an empty system? Assume that the units in the batch do not have to stay together; specifically, units are transferred to the next step the moment they are completed at any step. Assume step 1 needs to be set up before the beginning of production.
e. What batch size would you choose, assuming that all units of a batch stay together for the entire process?

Transcribed Image Text:

Step I Siep 3 Processing Time l Minute Part Processing Time 2 Minutes Part Processing Time 1.5 Minutes/ Part No Setup No Setup Setup Time: 20 Minutes