UNIVERSIDAD DE LA SABANA

OPERATION MANAGEMENT WORKSHOP

Capacity, Bottle neck & inventory game

1. A production plant is able to produce 1.000 units/h according to the manual. Every day they have to stop during
45 minutes in the first shift to re-start the principal machine. They also have to stop during 30 minutes per shift
for people recess and 15 minutes for cleaning at the end of each shift. Statistics say that they have non scheduled
stops in average 1 hour per day.
Calculate the rated, effective and real capacity per day that this plant has if the efficiency of the bottle neck is
80% and the efficiency of the other resources different to bottle neck is 75%. Take into account shifts of 8 hours.

2. The demand of a product is 2000 units/month. This is produced in a plant with a capacity of 5 units/hour. The
efficiency of the plant is 80%. Historical statistics say that they have stopped in average 2hour/day they work for
production problems. They need 6 hours per 48 hours of production for preventive maintenance.

a. (1.0) How many 8 hours shifts needs this plant at least to get the demand? Remember that in each shift
they need to stop 40 minutes to recess, 5S and others.
b. (0.5) Is able this plant to get the demand in 1 month if they just want to work at last 2 shifts/day?
c. (1.0) They want to manage in a better way the production process, so they decide to use a board with cards
for activities (To do – Doing – Done) and also cards to know the reorder point of inventory. Which
methodology that we saw in our expositions they have to use in order to get what they want?

Take into account a month with 30 days and 4 weekends.

3. In a soda production Plant they have 3 processes to get the final product: First they prepare the formula with
different raw materials and the capacity of this process is 12.000 liters/day. The second process is to fill bottles
with the formula, so they put 1 liter of formula in each bottle. The capacity of this process is 10.000 botles/day.
Finally the packaging process: They put 10 bottles in a box. This process has a capacity of 1.600 boxes/day. The
plant produce each day the máximum production capacity.

Suppose that one common day, they began with 700 boxes of sodas in stock. During the day, they sold 1.500
boxes of sodas. The general manager took 50 boxes of sodas for domestic consumption and the quality manager
took out of inventory 150 boxes of soda because the formula was out of specifications. On the other hand, a
customer sent back 200 boxes of soda because they didn’t arrive on time, so he didn’t want to accept them.

a. How many boxes of soda can this plant produce in one day?
b. How many boxes of soda they have at the end of this day in stock?