HOMEWORK 5

(Production smoothing)
Question 1: For the following figures

Product Daily Quantity

F 9
G 8
H 5
K 6

a) Determine the number of cycle per day for this set of products that achieves fairly
level production?
b) Determine the production quantity per cycle for this set of products that achieves
fairly level production? It is important to mention that the number of extra units
usually verify the number of units short.
Solution:
a.

Daily Daily Unit per Nearest multiple of

Product Units Short
Quantity cycle smallest quantity
F 9 9/5 1 9x1-5=4
G 8 8/5 1 8x1-5=3
H 5 5/5 1 5x1-5=0
K 6 6/5 1 6x1-5=1
So, the number of cycle per day for this set of products that achieves fairly level production is 5.
b.

Cycle 1 2 3 4 5
Pattern F(2)-G-H-K F(2)-G(2)-H-K F(2)-G(2)-H-K F(2)-G(2)-H-K F-G-H-K(2)

Extra Unit(s) F F-G F-G F-G K

1
Question 2: Total 1-shift production time available (excluding break time) is 7.5 hours.
There are 2 shifts per day. Average downtime per day (not included change over time) is 40
minutes.

Average demand per Cycle time per piece Average change over
Part#
day (pieces) (seconds) time (minutes)
A 250 40 50
B 350 45 50
Determine:
a) the available time for changeovers per day
b) the desirable number of changeovers per day and
c) best batch sizes
Solution:
a. The available time for changeovers per day
The production time available for 2 shift(excluding break time and downtime):
7.5 hours x 2 shifts =15 hours/day.
The total production time for part A is 250 pieces x 40 seconds/piece = 10,000 seconds.
The total production time for part B is 350 pieces x 45 seconds/piece = 15,750 seconds.
The available time for changeover is that we substract the total production time for both
parts and the average downtime per day (40 minutes) from the available time, we have:
15 x 60 - [(10,000 + 15,750)/ 60] – 40 = 430.83 minutes available for changeovers
b. The number of changeovers per day is calculated by dividing the average change over
time by the available time for changeover
number of changeovers = available time for changeover/ one set of CO
= 430.83 minutes/ (50 + 50) minutes = 4.3 changeovers = 4
c.
Batch size = Demand/number of changeovers
Lot size A = 250/4 pieces = 62.5
Lot size B = 350/4 pieces = 87.5