1. Currently the United States Department of State has a process for producing passports. Each passport...
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1. Currently the United States Department of State has a process for producing passports. Each passport application undergoes 5 different process steps. Staffing of the department is 200 workers. In the process represented below, Government labor rules insure that no overtime occurs. Additionally workers who complete their assigned production volume for the day may leave early without losing pay. As a result, the department is consistent in finishing their work each day. The department does tend to have long lead times. Assume a 7.5 hour work day. Passport booklets (items) are processed in boxes that contain 25 items. Capacities and inventory levels shown below are measured in items per day and items respectively. Determine the number of days of cycle time before any improvements in the process are made. Indicate how many days each operation I would take off in order to accomplish the work in progress reduction and determine the number of days of cycle time after the work in progress is reduced. Please round your answer to 1 decimal place. Production Control Application opening and scanning Avg Cap-50,000 V WIP Location 1 Max. 100,800 Avg.-63,000 Min.-31,500 ↓ Application Approval Avg Cap-75000 ↓ WIP Location 2 Max.-147,000 Avg. 73,500 Min 42,000 Passport content editing and layout Avg Cap-44,000 WIP Location 3 Max. 118,000 Avg-94,500 Min. $2,500 V Printing & Binding Avg Cap 55,000 ↓ WIP Location 4 Max 74,500 Avg. 56,000 Min. 21,750 V Packaging and addressing Avg Cap 65,000 ↓ USPS package pickup A. Number of days of cycle time currently (before any improvement occurs): days B. Number of days of cycle time after inventory reduction improvement) has occurred*: days C. How many days will each operation take off in order to accomplish the reduction? Operation Application opening and scanning Application Approval Passport content editing and layout Printing & Binding Packaging and addressing Days off *Note that this solution ignores the initial backlog of applications and only focuses on process time after the application is opened. Catching up on the backlog is a whole other problem. 1. Currently the United States Department of State has a process for producing passports. Each passport application undergoes 5 different process steps. Staffing of the department is 200 workers. In the process represented below, Government labor rules insure that no overtime occurs. Additionally workers who complete their assigned production volume for the day may leave early without losing pay. As a result, the department is consistent in finishing their work each day. The department does tend to have long lead times. Assume a 7.5 hour work day. Passport booklets (items) are processed in boxes that contain 25 items. Capacities and inventory levels shown below are measured in items per day and items respectively. Determine the number of days of cycle time before any improvements in the process are made. Indicate how many days each operation I would take off in order to accomplish the work in progress reduction and determine the number of days of cycle time after the work in progress is reduced. Please round your answer to 1 decimal place. Production Control Application opening and scanning Avg Cap-50,000 V WIP Location 1 Max. 100,800 Avg.-63,000 Min.-31,500 ↓ Application Approval Avg Cap-75000 ↓ WIP Location 2 Max.-147,000 Avg. 73,500 Min 42,000 Passport content editing and layout Avg Cap-44,000 WIP Location 3 Max. 118,000 Avg-94,500 Min. $2,500 V Printing & Binding Avg Cap 55,000 ↓ WIP Location 4 Max 74,500 Avg. 56,000 Min. 21,750 V Packaging and addressing Avg Cap 65,000 ↓ USPS package pickup A. Number of days of cycle time currently (before any improvement occurs): days B. Number of days of cycle time after inventory reduction improvement) has occurred*: days C. How many days will each operation take off in order to accomplish the reduction? Operation Application opening and scanning Application Approval Passport content editing and layout Printing & Binding Packaging and addressing Days off *Note that this solution ignores the initial backlog of applications and only focuses on process time after the application is opened. Catching up on the backlog is a whole other problem.
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