There are four steps in the manufacturing process of a stuffed toy: cutting, stuffing, sealing, and packaging. There are two employees each for cutting and stuffing but one each for sealing and packaging. The processing times of cutting, stuffing, sealing, and packaging are 8, 5, 3, and 2 seconds per toy per employee.a) What is the cycle time for stage "cutting" (in [min/unit])?b) What is the cycle time for stage "sealing" (in [min/unit])?c) Which stage is the bottleneck? What is the process capacity in [units/hour]?d) If you can add one employee in parallel at the bottleneck stage, what should be the capacity of a new employee so that you increase the process capacity as much as possible?

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Answer:

(a) 2min/15units

(b) 1min/20units

(c) The bottleneck stage is cutting. The process capacity is 450units/hour

(d) The capacity of the new employee should be 1unit/2sec. The process capacity will increase four times

Step-by-step explanation:

(a) Cycle time for stage cutting for 2 employees = 16sec/2units × 1min/60sec = 2min/15units

(b) Cycle time for stage sealing for 1 employee = 3sec/1unit × 1min/60sec = 1min/20units

(c) Process capacity of stage cutting = 15units/2min × 60min/1hour = 450units/hour

(d) If the capacity of the new employee is 1unit/2sec, the process capacity = 1unit/2sec × 3600sec/1hour = 1800units/hour. The process capacity increases 4 times (1800/450 = 4)

Cycle time is the amount of time that is taken to complete a specific from task. The capacity of the new employee must be 1 unit/2sec.

What is cycle time?

The cycle time is the amount of time that is taken to complete a specific from task from start to finish.

A.) As we know that in the step one has 2 employees and the time taken by each of the employees to make a toy is 8 sec, therefore, it will take 8 seconds to produce two units(one by each employee). Thus, the Cycle time for step one for 2 employees can be written as,

[tex]\begin{aligned}\text{Cycle time for First stage for 2 employees} &= 8\ sec \times \dfrac{1\ min}{60\ sec}\\\\&= 2\ min/15\ units\end{aligned}[/tex]

B.) As we know that the sealing step has only 1 employee and the time taken by each of the employees to seal a toy is 3 sec, therefore, it will take 3 seconds to produce one unit. Thus, the Cycle time for step Sealing can be written as,

[tex]\begin{aligned}\text{Cycle time for stage Sealing} &= 3\ sec \times \dfrac{1\ min}{60\ sec}\\\\&= 1\ min/20\ units\end{aligned}[/tex]

C.) The step of the plant that is the bottle neck is the First step.

Now, As we know that in the step one has 2 employees and the time taken by each of the employees to make a toy is 8 sec, therefore, it will take 8 seconds to produce two units(one by each employee). Thus, the Process capacity of step one can be written as,

[tex]\text{Process capacity of First stage} &= \dfrac{15\ units}{2\ mins }\times \dfrac{60\ min}{1\ hour}\\[/tex]

                                                    [tex]&= 450units/hour[/tex]

D.) If you add one employee in parallel at the bottleneck step, and the capacity of the new employee is 1unit/2sec, then the processing capacity  of the new plant can be written as,

[tex]\rm \text{The processing capacity of the new plant} = \dfrac{1\ unit}{2\ sec}\times \dfrac{3600\ sec}{1\ hour} = 180\ Units/hour[/tex]

Now, as we see that the process of the new capacity increases 4 times as compared to the plant capacity of the plant before, therefore, the capacity of the new employee must be 1 unit/2sec.

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