QUESTION 1 Peter’s Paper Clips uses a three -stage production process: cutting wire to prescribed lengths, inner bending, and outer bending. The cutting process can produce at a rate of 200 pie ...

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QUESTION 1
Peter’s Paper Clips uses a three -stage production process: cutting wire to prescribed lengths,
inner bending, and outer bending. The cutting process can produce at a rate of 200 pieces per
minute; inner bending, 220 pieces per minute; and outer bending, 110 pieces per minute.
Determine the hourly capacity of each process stage and the number of machines needed to
meet an output rate of 30,000 units per hour. Round your answers for the hourly capacity of
each process stage to the nearest whole mum ber. Round your answers up for the number of
machines needed to a whole number.
Cutting process:
Hourly capacity: pieces/hour
Number of machines needed: machine(s)
Inner bending:
Ho urly capacity: pieces/hour
Number of machines needed: machine(s)
Outer bending:
Hourly capacity: pieces/hour
Number of machines needed: machine(s)


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Solution
Cutting:

(200/min)(60 min/hour) = 12,000/hour;

30,000 / 12,000 = 2.50. Need to round up to 3 machines to ensure meeting the
required output rate.
Inner b ending:
12000 3 13200 3 6600 5

(220/min)(60 min/hour) = 13,200/hour;

30,000 / 13,200 = 2.27. Need 3 machines.
Outer bending:

(110/min)(60 min/hour) = 6,600/hour;

30,000 / 6,600 = 4.55. Need 5 machines.


QUESTION 2
An assembly line with 30 activities is to be balanced. Th e total amount of time to complete all
30 activities is 60 minutes. The longest activity takes 2.5 minutes and the shortest takes 0.8
minute. The line will operate for 300 minutes per day.
a. What are the maximum and minimum cycle times? Round your answers to one decimal
place.
Maximum cycle time: minutes
Minimum cycle time: minutes
b. How much daily output will be achieved by each of those cycle times? Round your
answers to the nearest w hole number.
Daily output achieved by maximum cycle time: units/day
Daily output achieved by minimum cycle time: units/day


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Soluti on
a.
Maximum cycle time = 60 minutes

Minimum cycle time = 2.5 minutes
b. CT = A/R 2.5 2.0 120 150

Rmax CT = 300/60
= 5 units/day;
Rmin CT = 300/2.5
= 120 units/day;


QUESTION 3
A small assembly line for the assembly of power steering pum ps needs to be balanced.
Precedence diagram is shown below.

The cycle time is determined to be 1.9 minutes. How would the line be balanced by choosing
the assignable task having the longest task time first? Fill in the table below. If your answer is
zer o, enter "0". Round your answers to one decimal place.
Station Tasks Total Time Idle Time
1 B,A,C,D
2 E,F
3 G,H,I 1.7 0.2 1.7 0.2 1.2 0.7

Total
What is the assembly -line efficiency? Round your answer to one decimal place.
%