CHAPTER 8 Problems d. Explain your answers to a, b, and c. e. How would the analysis change if department A achieved an 85% yield? Recalculate a, b, and c. A B C Department Capacity (Parts/Hour) A 120 B 110 C 140 D 160 D 5. Macro Galvanizing coats sheet steel for the appliance industry in its plant in Gary, Indiana. Macro has one production line that can coat steel up to 72 inches wide. The production line runs 80 hours per week. Regardless of width, the steel is processed at 200 feet per minute. Macro processes only the three widths of steel listed here: Width (in.) Product Mix 36 0.30 50 0.25 60 0.45 a. What is the capacity of Macro's production line in square feet of steel coated per week? b. What is the capacity in square feet per week if the mix changes to 0.40, 0.40, and 0.20, respectively? c. What is the capacity in square feet per week if the mix does not change and Macro decides to use 10% overtime per week? d. What is the capacity in square feet per week if the mix does not change, there is no overtime, and Macro experiences 5% unplanned downtime? e. What is the capacity in square feet per week if the mix does not change, there is no overtime, and Macro's engineers find a way to run the line at 220 feet per minute? 6. Monique Food Processing Company produces light snacks that can be heated in a microwave. The following steps are included in the process: von70154_08_c08_223-256.indd 251 Steps Description Capacity (Units/Hour) 1 Prepare food 200 2 Measure and place in plastic pouch 175 3 Prepare cardboard box 200 4 Insert pouch into box 300 5 Shrink-wrap box 200 2/22/13 3:35 PM CHAPTER 8 Problems a. What is the system capacity, and which is the bottleneck department? b. How much slack (unused capacity) is available in other departments? c. How much system capacity can be gained by adding capacity to the bottleneck? 7. Botkins Bicycle Shop manufactures 10-speed bikes. The assembly process requires the components listed below. Botkins can assemble approximately 350 bicycles per week without overtime. The labor contract allows Botkins' management to add up to 10% overtime to assembly operations. Component Quantity per Finished Bicycle Source Capacity (Units/Week) Wheels 2 Internal 750 Tires 2 External 900 Frame 1 Internal 400 Brakes 2 External 950 Handle bars 1 Internal 600 Pedal and drive sprocket subassembly 1 Internal 500 a. What is the capacity of the facility without using overtime? Which is the bottleneck department(s)? b. What is the capacity of the facility with overtime? Which is the bottleneck department(s)? c. What increases in department capacity would be required to increase system capacity to 450 units per week? 8. The Mills Brothers Cereal Company makes a wheat and raisin cereal on one of its production lines. One pound of raisins is required for four pounds of wheat flakes in order to make five pounds of cereal. The following steps are included in the process: von70154_08_c08_223-256.indd 252 Step Description Capacity (Pounds/Hour) A Crush wheat 1,400 B Form flakes 1,200 C Toast flakes 1,600 D Coat raisins 250 E Mix cereal and raisins 1,200 F Put mixture in box 1,100 G Place boxes in shipping containers 1,400 2/22/13 3:35 PM