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POM 2010-160 Production and Operations Management Assignment 2 1. Up, Up, and Away is a producer of kites and wind socks. Relevant data on a bottleneck operation in the shop for the upcoming fiscal year are given in the following table: Item Demand Forecast Lot Sire Standard processing time Standard setup time Kites 30,000 unitsyear 20 units 0.3 hour/unit 3.0 hourslot Wind Socks 12,000 units/year 70 units 1. Ohour/unit 4.0 hourslot The shop works two shifts per day, 8 hours per shift, 200 days per year. Currently, the company operates four machines, and desires a 25 percent capacity cushion. How many machines should be purchased to meet the upcoming year's demand without resorting to any short-term capacity solutions? a 2. Johnson Cogs wants to set up a line to serve 60 custom-ers per hour. The work elements and their precedence relationships are shown in the following table. 1. What is the theoretical minimum number of stations? b. How many stations are required using the longest work element decision rule? c. Suppose that a solution requiring five stations is obtained. What is its efficiency? Work Element Time (See) Immediate Predecessors ($) A 40 None B 30 A SO A D 40 B E 6 B F 25 G 15 H 20 DE I 18 F G J 30 HI Total 274 1 3. You are asked to analyze the Kanban system of LeWin, a French manufacturer of gaming devices. One of the workstations feeding the assembly line produces part M670N. The daily demand for M670N is 1,800 units. The average processing time per unit is 0.003 day. LeWin's records show that the average container spends 1.05 days waiting at the feeder workstation. The container for M670N can hold 300 units. Twelve containers are authorized for the part. Recall that is the average processing time per container, not per individual part. 2. Find the value of the policy variable, a, that expresses the amount of implied safety stock in this system b. Use the implied value of a from part (a) to determine the required reduction in waiting time if one container was removed. Assume that all other parameters remain constant