Subject: Warehouse management and Inventory control_20BLGV01
Team 4
No. Full name Student ID
1 Vũ Nguyễn Yến Nhi 2000005135
2 Phạm Thị Tường Vân 2000005741
3 Nguyễn Trương Phúc Hậu 2000001348
4 Nguyễn Phương Phi Trường 2000003698
ASSIGNMENT 3 – CHAPTER 3
Discuss question
6.1. Shop order 7777 is for 600 of part 8900. From the routing file, it is found that operation
20 is done on work center 300. The setup time is 3.5 hours, and run time is 0.233 hours per
piece. What is the required capacity on work center 300 for shop order 7777?
Work Time =Setup +Run Time
=3.5 hours + (0.233 hrs/parts X 600 parts)
=3.5 hrs+139.8
=143.3 hours
6.2. An order for 100 of a product is processed on work centers A and B. The setup time on A
is 50 minutes, and run time is 5 minutes per piece. The setup time on B is 60 minutes, and the
run time is 5 minutes per piece. Wait time between the two operations is 5 hours. The move
time between A and B is 40 minutes. Wait time after operation B is 5 hours, and the move
time into stores is 3 hours. Queue at work center A is 25 hours and at B is 35 hours. Calculate
the total manufacturing lead time for the order. Answer. 92 hours and 10 minutes
Work Time = Setup + Run time
A = 50 min+(100 X 5) = 550 min
Wait Time = 300 min
Move Time A to B = 40 min
Queue = 1500 min
B = 60 min + (100 X 5) = 560 min
Wait Time = 300 min
Move Time B to Store = 180 min
Queue = 2100 min
Total = 5530 / 60 = 92 hours 10 mins
6.3. In problem 6.2, what percentage of the time is the order actually running? Answer.
18.08%
Run Times
A = 500
B = 500
A+B/Total =1000 / 5530 = 18.08 %
6.4. An order for 50 of a product is processed on work centers A and B. The setup time on A is
45 minutes, and run time is 5 minutes per piece. The setup time on B is 30 minutes, and the
run time is 4 minutes per piece. Wait time between the two operations is 8 hours. The move
time between A and B is 60 minutes. Wait time after operation B is 8 hours, and the move
time into stores is 2 hours. Queue at work center A is 40 hours and at B is 35 hours. Calculate
the total manufacturing lead time for the order.
Working time in A: (50*5) + 45= 295 minute
Working time in B: (50*4) + 30 = 230 minute
Standby time and moving time = 8 hour + 1 hour = 9 hour = 540
Standby time after operation of B and the time of movement into the store = 8 hour + 2 hour = 10
hours = 600
Stand in the center A and B = 40 hours + 35 hours = 75 hours = 4500
The total manufacturing lead time for the order = 75h + 9h + 10h + 3h50 + 4h55 = 103 hours 15
minute = 6165 minutes
6.5. In problem 6.4, what percentage of time is the order actually running?
The order actually running = (50 * 5) + (50*4) = 450 minutes
The percentage of time = (450/6165) *100% = 7,299 %
6.6. Amalgamated Skyhooks, Inc., has an order for 200 Model SKY3 Skyhooks for delivery on
day 200. The Skyhook consists of three parts. Components B and C form subassembly A.
Subassembly A and component D form the final assembly. Following are the work centers
and times for each operation. Using a piece of graph paper, draw a backward schedule based
on the following. When must component C be started to meet the delivery date?
a. Only one machine is assigned to each operation.
b. The factory works one 8-hour shift, 5 days a week. c. All parts move in one lot of 200.
Part Operation Standard time (days)
D 10 5
20 7
B 10 5
20 7
C 10 12
20 5
Subassembly A 7
Final Assembly SKY3 5
177.92 180 182.92 185 187.92 192.92 195 197.92 200
Operatio
Operation Operation Operation Operation Operation Subassembly Final
n
10 for A 20 for A 10 for B 20 for B 10 for C A Assembly
20 for C
2.083333 2.916667 2.0833333 2.916667 5 2.083333 2.91666667 2.083333
6.7. International Door Slammers has an order to deliver 500 door slammers on day 130.
Draw up a backward schedule under the following conditions: a. Only one machine is
assigned to each operation. b. Schedule one 8-hour shift per day for 5 days per week. c. All
parts are to move in one lot of 500 pieces. d. Allow 8 hours between operations for queue and
move times. A slammer consists of three parts. Purchased components C and D form
subassembly A. Subassembly A and component B form the final assembly. Part B is machined
in three operations. No special tooling is required except for part B, operation 20. It takes 24
hours to make the tooling. Material is available for all parts. Standard times for the lot of 500
are as follows:
76.05 86.47 days 87.47 90.47 98.8 days 99.8 106.05 days 124 days 130 days
days days days days
Operation 10 Queue Tolling Operation Queue Operation Subassembly Final
and 20 and 30 A Assembly
move move
10.42 days 1 day 3 days 8.33 days 1 day 6.25 days 18.75 days = 5.2 days
=10*500/60/ = 8/8 = 24/8 = = 8/8 =6*500/60/8 18*500/60/8
8 8*500/60/8
6.8. An order for 100 of a product is processed on operation A and operation B. The setup
time on A is 50 minutes, and the run time per piece is 9 minutes. The setup time on B is 30
minutes, and the run time is 6 minutes per piece. It takes 20 minutes to move a lot between A
and B. Since this is a rush order, it is given top priority (president’s edict) and is run as soon
as it arrives at either workstation.
It is decided to overlap the two operations and to split the lot of 100 into two lots of 60 and 40.
When the first lot is finished on operation A, it is moved to operation B where it is set up and
run. Meanwhile, operation A completes the balance of the 100 units (40) and sends the units
over to operation B. These 40 units should arrive as operation B is completing the first batch
of 60; thus, operation B can continue without interruption until all 100 are completed.
a. Operation A
Total number of orders = 100
- Set up time A = 50 minutes
- Run time A = 9 minutes/ piece Run time = 100*9 = 900 minutes
- Move time from A to B = 20 minutes
Work time A = 50 + 900 + 20 = 970 minutes
- Set up time B = 30 minutes
- Run time B = 6 minutes/ piece Run time = 100*6= 600 minutes
Work time B = 30 + 600 =630 minutes
Total manufacturing lead time without overlapping = 970 + 630 = 1600 minutes
b. Operation B
Total number of orders = 100
- Set up time B = 30 minutes
- Run time B = 6 minutes/ piece Run time = 100*6= 600 minutes
Work time B = 30 + 600 = 630 minutes
- Set up time A = 50 minutes
- Run time A = 9 minutes/ piece Run time A = 60*9= 540 minutes
- Move time from A to B = 20 minutes
Work time A = 50 + 540 + 20 = 610 minutes
Total manufacturing lead time without overlapping = 630 + 610 = 1240 minutes
Time saving if the operations are overlapped = 1600 – 1240 = 360 minutes
6.9. An order for 250 bell ringers is processed on work centers 10 and 20. The setup and run
times are as follows. It is decided to overlap the lot on the two work centers and to split the lot
into two lots of 100 and 150. Move time between operations is 30 minutes. Work center 20
cannot be set up until the first lot arrives. Calculate the saving in manufacturing lead time.
Setup on A = 50 minutes
Run time on A = 5 minutes per piece
Setup on B = 100 minutes
Run time on B = 7 minutes per piece
Move time = 30 minutes
Work center 10 operation time = 50 + (250 * 5) = 1300 minutes
Work center 20 operation time = 100 + (250 * 7) = 1850 minutes
Total manufacturing lead time = 1300 + 1850 + 30 = 3180 minutes = 53 hours
Operation time for center 10 for a lot of 100 = 50 + (100 * 5) = 550 minutes
Operation time for center 20 for a lot of 150 = 100 + (150 * 7) = 1150 minutes
Total manufacturing lead time = 550 + 1150 + 30 = 1730 minutes = 28 hours 83 minutes
Saving manufacturing lead time = Total Manufacturing 1 – Total Manufacturing 2
Saving manufacturing lead time = 3180 – 1730 = 1450 minutes = 24 hour 16 minutes
6.10. An order for 100 of a product is processed on operation A. The setup time is 50 minutes,
and the run time per piece is 9 minutes. Since this is a rush order, it is to be split into two lots
of 50 each and run on two machines in the work center. The machines can be set up
simultaneously.
a. Calculate the manufacturing lead time if the 100 units are run on one machine.
Work center A operation time = 50 + (100 * 9) = 950 minutes
b. Calculate the manufacturing lead time when run on two machines simultaneously.
Work center A operation time = 50 + (50 * 9) = 500 minutes
c. Calculate the reduction in lead time.
Reduction in lead time = 950 - 500 = 450 minutes
6.11. What would be the reduction in manufacturing lead time if the second machine could
not be set up until the setup was completed on the first machine?
The manufacturing time will be reduced by 450 minutes
6.12. An order for 100 of a product is run on work center 40. The setup time is 4 hours, and
the run time is 3 minutes per piece. Since the order is a rush and there are two machines in
the work center, it is decided to split the order and run it on both machines. Calculate the
manufacturing lead time before and after splitting.
Lead time before splitting = 4 * 60 + (100 * 3) = 540 minutes
Lead time after splitting = 4 * 60 + (50 * 3) = 390 minutes
6.13. In problem 6.12, what would be the manufacturing lead time if the second machine
could not be set up until the setup on the first machine was completed? Would there be any
reduction in manufacturing lead time?
Lead time after splitting of the 2nd machine = (4 + 4) * 60 + (50 * 3) = 630 minutes
There is no reduction in production time
6.14. Complete the following input/output report. What are the planned and actual backlogs
at the end of period?
Period 1 2 3 4 total
Planned Input 35 38 36 39 148
Actual Input 33 33 31 40 137
Cumulative Variance -2 -7 -12 -11 -22
Planned output 40 40 40 40 160
Actual output 38 35 40 38 151
Cumulative Variance -2 -7 -7 -9 -18
Planned Backlog 32 27 25 21 20
Actual Backlog 32 27 25 16 18
The planned backlogs at the end of period = 20 units
The actual backlogs at the end of period = 18 units
6.15. Complete the following input/output report. What is the actual backlog at the end of
period 5?
Cumulative Variance 6 2 0 4 2
Planned Output 80 80 80 80 80 400
Actual Output 85 83 76 82 84 410
Cumulative Variance 5 3 -4 2 4
Planned Backlog 45 43 41 39 37
Actual Actual 45 44 41 43 43
6.16. Complete the following table to determine the run sequence for each of the sequencing
rules.
Sequencing Rule
Job Process Time (days) Arrival Date Due Date Operation Due Date
FCFS EDD ODD SPT
A 5 123 142 132 1 2 3 3
B 3 124 144 131 2 3 2 2
C 2 131 140 129 3 1 1 1
D 6 132 146 135 4 4 4 4
6.17. Jobs A, B, and C are in queue at work center 10 before being completed on work center
20. The following information pertains to the jobs and the work centers. For this problem,
there is no move time. Today is day 1. If the jobs are scheduled by the earliest due date, can
they be completed on time?
JOB WORK CENTER 10 WORK CENTER 20 DUE DATES
Start day Stop day Start day Stop day
A 1 8 8 11 12
C 8 17 17 21 18
B 17 22 22 24 24
Job C falls behind and they will not be able to complete that on time.
6.18. Calculate the critical ratios for the following orders and establish in what order they
should be run. Today’s date is 75.
Order Due Date Lead Time Remaining (days) Actual Time Remaining (days) CR
A 89 10 14 1.4
B 95 25 20 0.8
C 100 20 25 1.25
