Consider the following process that assembles a toy. There is a worker working at each workstation. For a typical 8-hour workday, from 8:00 A.M. to 4 P.M., find the followings. Assume that the process is in a steady-state (i.e., disregard the initial startup stage), producing no defective items.

Input --> Station 1 --> Station 2 --> Station 3 --> Output

(12 units/hr.) (6 units/hr.) (10 units/hr.)

(a) What is the cycle time and capacity (maximum output) per day of the current process assuming no one works overtime?

(b) How long will the 2nd and 3rd Stations have to work if the 1st Station works at the maximum capacity?

(c) Is there any benefit if we add another worker to Station 3 of the original process? Yes or no, explain why.

(d) For the first five units, using the original process, show the exact time each unit starts at the first Station and comes off the line. Also, indicate throughput time for each unit.