Consider a process with 4 processing stations as shown below

A

12 min

B

10 min

C

16 min

D

8 min

Currently each of the machines (one worker per machine) work completely during the 8 hour shift.

The piling up of inventory between various stations had prompted the company to hire you as a

consultant to solve the problem. After a simple process analysis, using principles of Synchronous

manufacturing, you have suggested the following

Reduce capacity utilisation of A, B and D to 75%, 62.5% and 50% levels. The workers adopted the

suggestion in the following way

A) Worker of Machine A started the machine late so that he can work continuously

B) Worker of Machine B decided to do clean up the machine for 20-25 minutes after every hour of

working

C) Worker D had offered the management to take up an extra work during the last four hours of

the shift

What will be the effect of these decisions on the factory performance? How many of these decisions

are feasible to implement. How will you solve the problem