Professional Documents
Culture Documents
Rajiv Misra
Team No - 6
Ankit Bhatnagar
Gurneet KaurBhatia
Pankaj Dhiman
Rohit Suri
Vineet Chauhan
PROCESS ANALYTICS HANDBOOK
Process 1
To begin, consider the three-step process model in the Process 1 tab. The process is staffed by
three workers: Alice is assigned to step A, Bob is assigned to step B, and Charlie is assigned
to step C. Please answer the questions below.
Process B
5 mins
12 per hour
4. What is the throughput time or a rush order (that is, an order arriving when the system is
empty that is moved through the process without delay)?
10 mins
66.67%
Process 2
Now that you have finished Process 1, consider the same process, but assume we assign
Betty, an additional worker, to a step B. Betty and Bob are equally qualified, and they are
told to split the work of step B (working simultaneously complete the 5 minutes of work on a
unit in half that time).
1. Before doing any calculations, which process metrics would you expect to change
relative to Process1
3 mins
20 units/hour
4. What is the throughput time for a rush order (that is, an order arriving when the
system is empty that is moved through the process without delay)?
10 mins
83%
Process 3
Look at Process 3, a variant of Process 1 ( 3 workers, Alice does step A, Bob step B, and
Charlie step C). However, assume that steps A and B can be completed in parallel, as shown
in the process diagram. (“In parallel” means that Alice can work on her component at the
same time as Bob works on his component. For example, Alice could be finishing a table top
at the same time Bob is finishing the four legs, and Charlie could be assembling the table by
attaching the legs to the table top.)
1. Before doing any calculations, which process metrics would you Process I?
Throughput time,
Workstation B
5 mins
12 units/hour
5. What is the throughput time for a rush order (that is an order arriving when the system
is empty that is moved through the process without delay)?
7 mins
66.67%
Process 1
To begin, consider the four – step process model in the Process 1 tab.
1. Calculate the amount of the time it would take to get a rush order through the process.
14.5 mins
12/hour
14.5 mins
72.5%
Process 2
For the process 2, assume that you have hired an additional worker (i.e., a fifth for the
process). This new worker is cross – trained at every step in process (can perform any of the 4
steps or any portion of any of the four steps). Inventory is permitted between steps so that the
cross –trained worker can move around freely. Assume no transportation time in moving from
one step to another.
1. At which step (s) does the worker spend the majority of his or her time?
A
For Process 3, you have the opportunity to send each of your four specialists to get additional
training in the other process steps. As a result of this training program, you will have five
workers available to you, each one cross-trained at each of the four process steps.
Process 4
Go to Process 4, a variant of Process 1. Your analysis was done with the assumption that no
inventory would be allowed to build up between steps. Answer these questions without that
assumption.
1. How would performance change if this restriction were relaxed? That is, what would
impact of allowing inventory to accumulate between steps?
Consider the following process in the Process 1 tab. All steps (A, B, C, D) are necessary to
create each finished unit. Each step employs a single worker who is not cross-trained for any
other processing times listed represent the amount of time each worker spends on a single
unit. There is not variability in processing times.
Process 1
1. What is the fastest that a rush order can go through the process?
35
32
Process 2
For the next two questions, consider a fifth step added to the process along with a fifth
worker. The fifth step, Step E, is done after Step C, and before Ste D, as depicted Process 2.
All steps (A, B, C, D, and E) are necessary to create each finished unit. Processing times are
shown for each process step.
3. What is the fastest that a rush order can go through the process?
40
32
Problem 4: Batch Processing Assignment Questions
Consider the following three-step worker- paced line in the Process 1 tab. Each step employs
a single worker who is not cross- trained for any other step. The setup represents the amount
of time the worker spends setting u e machine hatch. No units can be processed during setup.
The run time represents the amount of time it takes the worker to process a single unit. When
a worker completes a batch, he or she hands it off to the next stage.
Process 1
1. If only 10-unit batches are produced, what is the average capacity of the process per 8-
hour
4 batches
2. At what batch size does the bottleneck move? That is, at what batch size are there two
steps that are the bottleneck?
5 batches
Consider the six-step process in the Process 1 tab, where the processing time for each step is
uniformly distributed. Processing times can range from 12 to 18 minutes (any value in that
range is as likely to occur as any other in that range).
Process 1
2. If you could add one inventory buffer, where would you add it to maximize
capacity?
As the cycle time for each of the workstation varies with each simulation we
cannot determine exactly where to put the buffer in order to maximize the
capacity. It will vary depending on the actual time taken by each of the
workstation.
3. If you added a second unit of buffer to the same location as the first, what would be
the incremental impact on capacity of the second unit as compared with the first
unit?
Incremental impact of the second unit of buffer would be less as compared to the
first unit
consider the four-step worker paced line in the Process 1 tab. Each step employs a single
worker who is not cross-trained for any other step. The processing times listed represent the
amount of time each worker spends on a single unit. There is no variability in processing
times. Assume that all workers begin to work on the next unit as soon as they can.
Process 1
1. Assume that inventory is not permitted to accumulate - i.e., a unit cannot be passed to
the next stage until the worker receiving the unit is ready for it. What is the capacity
of the process?
3
Between A and B.
Between C and D
No effect
5. If a fifth worker were added to the process, what would the maximum capacity be?
Assume that you can add the fifth worker to anyone of the four tasks, that the worker
is not cross trained to do any of the other tasks and that the fifth worker works at the
same rate as the original worker doing that task.
4 per hour.
6. Instead, if a fifth worker who was cross – trained for all tasks were added to the
process, what would the new capacity be? Assume that this fifth worker incurs no
travel time in moving between Compare the labor utilization of the worker at Step 1
in the original situation (four workers, no inventory) and the situation with the
addition of the cross-trained fifth worker from the Four Step Process problem. How
does it change?
Krunchy Kreme, marking its famous doughnuts, begins with the three-step process shown in
Process 1. One dedicated worker mixes the dough and creates the doughnut shape from it.
Batches of doughnuts from the Shaping stage are processed in one of two identical machines
in the third step, staffed by one worker each. (Ignore the remaining steps in the process, such
as frying and packing, because they have ample capacity.) Assume that all setups are done by
the workers. A setup must be performed in each step of the process before every batch. Also,
assume that each worker is busy during the run time of his or her operation.
Process 1
1. Suppose that the batch size is 50 doughnuts. What is the capacity in an eight – hour day?
7 batches
84%
3. If Krunchy Kreme decides to change batch sizes, for what range of batch sizes is mixing
the bottleneck?
82 units
Process 1
For the processes in this assignment, we will explicitly account for variability in process time
with those process times distributed according to a uniform distribution. Thus, a process time
of 5 ±1 minutes/unit indicates that there is equal probability that the process (machine or
person) will have a process time of anywhere from four to six minutes/unit. There are no
setups.
For the rest of this part, consider four different production ,lines consisting of in-
series workstations with no buffers between stations. The numbers under e
workstation represent the process time per unit, in minutes.
2. Assuming that Line A has been operating for a while, the expected capacity of Line A is a.
Less than 6 units per hour
5.8
3. Is the utilization of the bottleneck step 100%? If so, why? If not, why not?
93.7%
Part B
Now assume that the second workstation feeds its defects to a rework station that performs a
delicate and lengthy task of disassembling the product and repairing it. Thus, it requires a
relatively long time (here, 40 minutes on average) to fix defects. There is an inventory buffer
in front of this rework step to accommodate for the unlikely case that there are several defects
in a row. While time- consuming, it still is successful only 90% of the time. When rework is
successful, the rework station passes the now- good unit to the third workstation in the line. If
it is not successful, the product is scrapped.
The third workstation, receiving reworked units, now has an average task time of 9 minutes.
6
Work station C
3. Is the utilization of the bottleneck step 100%? If so, why? If not, why not?
4. What is the yield of the process (the ratio of good finished product to items started in
the process)?
72%
Name of Group Members
Ankit Bhatnagar
Gurneet KaurBhatia
Pankaj Dhiman
Rohit Suri
Vineet Chauhan
GENERAL QUESTIONS
1.0 What were the major learning’s from this simulation
We learned new various new concepts. The concepts like yield of the process,
labour utilization, average labour utilization.
In addition the learning were to utilize the simulations for use of project
analysis.
2.0 Formulate a problem (like the ones you have done in this simulation) which
you would like to assign to the BM Juniors if you are the instructor of
Operations I. Also provide the answer and the logic of giving the question
The above mentioned diagram shows a process flow consisting of total of 7
processes. Processes A,B and C work in parallel. Similarly process D&E. In addition
work time is also given. Calculate the following.
E. If one additional worker is assigned to both D&E what will be the new
bottleneck?
Ans. The new bottleneck would be either B/C/F as they would take the maximum
time.