Problem 2 (50 points) (Quality-Yield-Costs) Consider a printer circuit board manufacturing process. After processing and electrical testing/inspection, good PCB's are sent to packaging and shipping, and defective parts are sent to a Rework station. After rework, good parts are sent back to Testing and packaging/shipping, while bad parts are sent to a Scrap station for disposal. Only 20% of the PCB's reworked can be recovered as good parts. (Assume no failures at this stage). The processing and Rework stations have a yield of 70% and 30%, respectively. The table below shows the stages and costs incurred at each stage. Stage Processing Testing/Inspection Packing/shipping Rework Scrap Costs per PCB unit $30 $15 $10 $20 $5 a) Draw the material flow process and assume total units =x. Also, list out the yield equations and material flows at every stage of the process including costs of the stage. (10 points) [Please label all parts of the process and add the equations on the arrows corresponding to the relevant stages). Make the diagram big so it is clear to grade. b) Assume x= 2500 PCB's what is the total yield or number of good PCB's? (10 points) c) What is the scrapped amount? Check material balance flows: Are inputs equal to outputs? (10 points) d) What is the cost per PCB yield. Provide response upto 2 decimals using a table (10 points). (Do note that reworked portions go back to testing first.) e) If a process improvement addressing internal failure improves the recovery rate of reworked parts from 20% to 30% i) what happens to yield? (10 points)