1. (a) Identify the bottleneck activity on this operation process chart.

(b) What is the cycle time for the bottleneck activity? (c) Calculate the number of teakettles that can be produced in an 8 hour shift (400 min.), assuming that one worker is assigned to handle each production activity (including operation, inspection and assembly).(d) Explain why this is not an efficient way (i.e., one worker per operation) to produce teakettles.

2. Assume that the activities on each vertical line may be combined to improve the production line efficiency and the bottleneck activity is still assigned with one worker.(a) Based on the bottleneck stations cycle time obtain in Problem 1(b) above, find the minimum number of workers needed to produce the teakettles required in Problem 1(c) above.(b) Describe each workers duties based on his/her new task assignment. Also, calculate the cycle time for each operator. For example

Operator 1: Operations 10 and 20. Cycle time: 1.32 min.

Operator 2: Operation 30 and Inspection 40. Cycle time: 0.33 min.

Returning to the teakettle example, Figure 4.3 presents the operating process chart for that item. Preparing such a chart is essentially the task of detailing the assembly chart (Figure 4.1), showing every operation and inspection that each part needs as it progresses from raw material to the final assembly. Handle 10 10 10 10 Spout Cut tube 0.210 min Upper lid part Molding process 1.200 min Cutting the section 1.320 min 10 Lid lever Molding rocess 1.200 min Cutting the section 1.320 min Base Punch and draw 0.210 min 10 Body Punch out 0.210 min 20 20 20 Molding process 1.200 min Cutting the section 1.320 min Drill hole 1.530 min Inspection 0.312 min 20 Deep draw 0.420 min 20 30 Drill hole 1.530 min 30 Inspection 1.410 min 30 Inspection 0.502 min 30 40 40 Inspection 1.650 min Drill nut hole 1.770 min AB Welding 50 Inspection 1.890 min SAI Roll pin Assemble three parts 4.250 min body to base 2.550 min A2 Welding spout to body 4.510 min Sand off excess weld 6.750 min A4 Buffing for finishing 8.450 min Screw handle A5 to body 10.520 min 40 Inspection 10.622 min Screws Returning to the teakettle example, Figure 4.3 presents the operating process chart for that item. Preparing such a chart is essentially the task of detailing the assembly chart (Figure 4.1), showing every operation and inspection that each part needs as it progresses from raw material to the final assembly. Handle 10 10 10 10 Spout Cut tube 0.210 min Upper lid part Molding process 1.200 min Cutting the section 1.320 min 10 Lid lever Molding rocess 1.200 min Cutting the section 1.320 min Base Punch and draw 0.210 min 10 Body Punch out 0.210 min 20 20 20 Molding process 1.200 min Cutting the section 1.320 min Drill hole 1.530 min Inspection 0.312 min 20 Deep draw 0.420 min 20 30 Drill hole 1.530 min 30 Inspection 1.410 min 30 Inspection 0.502 min 30 40 40 Inspection 1.650 min Drill nut hole 1.770 min AB Welding 50 Inspection 1.890 min SAI Roll pin Assemble three parts 4.250 min body to base 2.550 min A2 Welding spout to body 4.510 min Sand off excess weld 6.750 min A4 Buffing for finishing 8.450 min Screw handle A5 to body 10.520 min 40 Inspection 10.622 min Screws