Chapter 16: exercise 16.

3
&
Production & Quality Management
Group :3
Members :
Panji Malik Subhani (1706019053)
Aqiel Saiful Fatah (1706064302)
M. Raja (1906379106)

October 2020
Exercise 16.3

Rick Wing has a repetitive manufacturing plant producing automobile steering wheels. Use the following
data to prepare for a reduced lot size. The firm uses a work year of 305 days.
a) What is the setup cost, based on the desired lot size?
b) What is the setup time, based on $40 per hour setup labor?
 Exercise 16.3

Known,
D = Annual Demand = 30,500
d = Daily Demand = 100
p = Daily Production Rate = 800
Qp = EOQ desired = 200
H = Holding Cost = $10 per unit per year
Hourly labour rate= $40
S = to be determined
Setup time = to be determined

From calculation
S = $5.74 (a)
Setup time = setup cost/hourly labour rate
= $5.74/$40
= 0.1435 hour = 8.61 minutes (b)
 Case Study: Lean Operations at Alaska Airlines

Discussion Questions
1. What are the key ingredients of Lean, as identified at Alaska Airlines?
2. As an initial phase of a kaizen event, discuss the many ways passengers can be loaded and unloaded
from airplanes.
3. Document the research that is being done on the aircraft passenger-loading problem.
What are the key ingredients of Lean, as identified at Alaska
Airlines?
Lean Tools
In this case, Alaskan airlines is applying the
following tools:
● The 5S to identify aircraft ground
equipment and its location on the tarmac
● Utilization of “switchback” staircase for
unloading passengers through the rear
door, which saves two minutes, or nearly
17%, off previous unloading time
Lean
Lean Culture
● making performance relevant to Alaska
Airlines’ empowered employees.
● extensive lean training and workshop
Lean Concepts
● Focus on continuous improvements
● Reduce waiting/delay time by Improving
preparation for and synchronization of the
arrival and departure sequences,
Redefining the disconnect procedure for
tow bars used to “push back” aircraft at
departure time, and Pilot staffing
improvement.
Lean Planning
● metrics that measure performance
against targets
As an initial phase of a kaizen event, discuss the many ways
passengers can be loaded and unloaded from airplanes

Steffan Method

In this approach, often called the Steffen method, adjacent passengers in line will be
seated two rows apart from each other. The first wave of passengers would be, in
order, 30A, 28A, 26A, 24A, and so on, starting from the back. (For a typical airplane
there would be 12 such waves, one for each seat in a row and for odd and even
rows.)

In field tests, this method has outperformed all others. In a test with 72 passengers it
was nearly twice as fast as boarding back-to-front or in rotating blocks of rows,
methods commonly used in the industry. It was 20 to 30 percent faster than
more-optimized boarding methods such as random boarding, when people get on
without regard to where their assigned seats are. It also beat boarding
windows-middle-aisle. My method even outperformed the industry gold standard of
open seating, used by Southwest airlines.
Document the research that
passenger-loading problem
Paper 1
The Human Factor in the
Paper Title Passenger Boarding Process at
the Airport
Author(s) Kierzkowski and Kisiel
Year of
2017
Publication
To present the human factor that
can have an important influence
Objective
on the process of carrying out
the boarding of passengers.
Method Statistical Analysis
The number of aisle seats and
passengers behaviour in storing
Key Findings
hand carries highly influence the
aisle interference
doi:
Link/DOI
10.1016/j.proeng.2017.04.385
is being done on the aircraft
Paper 2
Identifying bottlenecks and designing
ideas and solutions for improving aircraft
passengers’ experience during boarding
and disembarking
Suzanne Hiemstra-Van
Mastrigta, Richard Ottens, Peter
Vinka.
2019
To observe passenger behaviour
during boarding process, identify
bottlenecks during the process, and
provide solutions to these
bottlenecks
Observational Research
The main bottlenecks are hand
luggage, lack of preparation by
passengers, and communication
doi:
10.1016/j.apergo.2018.12.016
Paper 3
The air cargo load planning problem - a
consolidated problem definition and
literature review on related problems
Felix Brandt
2018
to describes the operational load
planning problems of air cargo
carriers
Observational Research
in the literaturethe term air cargo
loading is used ambiguously for
different subproblems that appear
during the loadplanning process
for a flight
DOI:
10.1016/j.ejor.2018.07.013