WORKSHOP BALANCE OF MATERIALS

A manufacturing company produces two kinds of products X, Y, from raw materials

E, C. X and Y are related in such a way that the production of Y in kilograms is five
times larger than the production of X. Raw materials are used as follows: 1750 Kg
of E and 150 Kg of C with a non-usable waste of 100 kg for an 8 hour shift.
The company now intends to expand its plant integrating it vertically, so it can
manufacture one of the raw materials, E, with the subsequent drop in production
costs.
Reviewing the technical literature managers found the following process for
manufacturing product E:
- Raw materials A and B are used as inputs.
- Consumption of A in Kg is 8/7 of E.
- Consumption of B in Kg is 4/7 of E.
Product E is made in two stages:
In the first stage raw material A undergoes a process (R) which generates a
byproduct M (Equivalent by weight to 25% of A) and an intermediate product D.
The production of D in kg corresponds to 70% of the weight of A. During the
process (R) there is a non-recoverable manufacturing loss.
In the second production stage, the intermediate product D undergoes a new process
(S) with raw material B.
The production process (S) with materials D and B generates losses corresponding
by weight to 5% of raw material B employed in the process.
In the same production process (S), a byproduct N is generated in a proportion
equivalent by weight to 25% of the sum of the weights of materials D and B.
Process (S) generates a product E, which is currently used as raw material for the
plant.
The production by weight of material E, obtained from process (S) corresponds to
35/48 of the combined weight of materials D and B.
Requested:
1. - Make a flowchart of the current process of the factory.
2. - Determine the current daily production of final products X and Y (before the
expansion).
3. - Make a flowchart of the new factory production, integrating it with the current
one.
4. - Determine the daily needs of raw material inputs A and B in order to obtain, in
the new factory (that is, in the integrated solution), the same current production of X
and Y.
5. - Determine the production of byproducts M and N, resulting in the new
production scheme.
6. - Determine Kg losses in processes (R) and (S).
7.- How would you check the results as correct?
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