IEE 561 - PRODUCTION SYSTEMS

Homework#1 Solutions

Problem 1.1

Manufacturing system models are built because real systems are too complex to understand thoroughly
and it is too risky and expensive to experiment on actual systems.

Primary uses of systems models include

1) Optimization of system decision variables;

2) Prediction of system performance if a specific plan is implemented;
3) Aid in controlling the system and selecting appropriate operating rules;
4) Providing insight into the performance of the system including detection of important
interactions and critical parameters (a critical parameter is one for which small perturbations
may result in large shifts in system performance); and
5) Justification and communication of decisions.

Problem 1.4

𝑃𝑟(𝑎𝑙𝑙 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔) = 0.958 = 0.663

Problem 1.14

a) Process layout
b) (10,000 is very high, too high in fact, but) product layout
c) Cellular (group) or product
d) Cellular (group)
e) Product (possibly a mixed product flow line)

Problem 1.15

𝑊𝐼𝑃 = 𝑃𝑅 × 𝑇𝑇

𝑊𝐼𝑃 800
𝑇𝑇 = = = 3.2 𝑑𝑎𝑦𝑠
𝑃𝑅 250

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Problem 1.16

𝑊𝐼𝑃 = 𝑃𝑅 × 𝑇𝑇

0=current, 1=new

1. 5 𝑑𝑎𝑦𝑠 = 𝑃𝑅0 × 𝑇𝑇0

2. 10 𝑑𝑎𝑦𝑠 = 𝑃𝑅1 × 𝑇𝑇1 where 𝑃𝑅1 = 1.2𝑃𝑅0

or 8.33̅ 𝑑𝑎𝑦𝑠 = 𝑃𝑅0 × 𝑇𝑇1

𝑇𝑇1 ̅
Thus, ⁄𝑇𝑇 = 8.33⁄5 = 1.67
0

Throughout time increases by 67%.

Problem 2

An R&D lab required 40 labor hours to assemble the first prototype of a new product. The
second prototype required 32 labor hours. Assuming a consistent learning rate how many hours
would you expect to be required to assemble the 100th unit?

Problem 3

A manufacturing system has 12 machines. Each machine can be in any of three states
(operational, waiting for repair, being repaired). How many possible states are there for the
system?

312

Problem 4

A software system consists of ten programs.

a. What is the maximum number of potential interfaces between programs?

2
 𝑚(𝑚 − 1)
= 45
2
b. Suppose each program is connected to two other programs. How many interfaces are there in
total?

10 (You can sketch a simple example to see why)

Problem 5

Explain the impact of reducing setup cost on the overall performance of a manufacturing system.

The setup cost reduction will help reduce the cost for each product, thus bringing more profit if
the market price of the product stays the same, else it can help maintain a competitive price for
the product. Moreover, if reducing the setup cost corresponds to reducing the setup time, the
throughput time will decrease, and on average less Work-In-Progress as a result. This can lead to
a more flexible manufacturing system. Shorter forecasting horizons, and quicker detection of out
of control production can be other benefits.

Problem 6

A manufacturing system has six stages in series. Each stage has a reliability of 80%.

a. What is the reliability of the system?

b. Suppose you added a parallel processor to each stage and the stage was operational if one or
both processors was operational. What is the reliability of the system?

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 IEE 561 - PRODUCTION SYSTEMS

Homework#1 Solutions

Problem 2.2

Each has its own advantages. Here, we name a few:

Problem 2.3

Problem 2.4

Problem 2.10

a) The sum of all task times is 154 and the cycle time is 40. So, the lower bound on the number of
workstations is 4.

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b)

c) The lower bound is 4. The number of workstations from the ranked positional weight technique (the
upper bound) is 5. The lower bound is not reached, hence, we cannot guarantee that the solution is
optimal.

Problem 2.11

2
Problem 2.13

87
b) C=30, ⌈ ⌉= 3
30
c)

d) Task d dominates e

e)

3
Problem 2.23

4
5
6
Problem 2.28

370.5
C=100, ⌈ 100 ⌉= 4

7
8
Problem 2.35

9
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