10 October Rhodes Lecture Theatre Week 1.1. Pre-Readings Assignment Questions

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1 Pre-Readings Assignment Questions Class Notes Cash Study: Donner How long will an 8 board order take? How much labor goes into an order? When do you use CNC drill over manual?

2 Pre-Readings Process Analysis See Harvard Business Publishing App for notes Putting together processes, particularly for service organizations, that help achieve firm and customer goals more easily I think I m going to love this class Sequential Processes Decision nodes Parallel processes Batch Processes Better for processing multiple things at once E.g. Disneyland rides Assessing Capacity Key to discover/address bottlenecks Tasks ahead of bottleneck are blocked tasks Tasks afterwards are starved tasks 1 c apacity = Labor Utilization cycle time Similar equation used for capital utilization, material utilization, energy utilization Quality & Speed Quality Performance Typically what we think of Conformance Very important in operations, e.g. bug-free software Speed Throughput time Minimum and average Flexibility Dimensions Time Horizons Elements Range Uniformity Mobility Safety

3 Assignment Questions What is the normal process flow of the production system at Donner? Draw a diagram capturing the process flow. What orders would you schedule on the CNC drill? On the CNC router? The CNC drill takes 8 times as long as the manual drill to prep, but can process 20 times as fast. Total run time on the CNC drill is lower in September than manual drill, and had an output over 5 times larger. Current policy has only orders over 100 boards drilled by CNC; I would lower this threshold to 50 to process an additional 200+ boards in September more quickly. The CNC router preps 3 times slower than the punch press, but processes 2 times as fast. Total run time on the CNC drill is lower in September than manual punching, and had an output over 4 times larger. Since orders over 1000 boards are given five weeks to complete, I would use the CNC drill on these orders primarily to cut down processing time. I would also leverage the CNC drill for the 4-day rush orders, as they can process the order faster, and take up the idle time current manual drillers have in preparation. What is the capacity of the Dry Film Photoresist area? (assume the order size is eight). How does capacity change with order size? Capacity = 1/cycle time Capacity increases with order size What is the standard labour time for an order of 1 board? 8 boards? 200 boards? (in other words, how much labour is expended to produce the order) min; min; 3900 min?

4 Class Notes Assessment Written exam in January Review session week 9 Discovery simulation week 5 Electives of note Cybersecurity Project Management Service Management Cash Study: Donner Update answers from Homework Process: Inspect & Shear 20 min. Prep time 0.5 min/panel Run time Artwork Generation (parallel to Inspect & Shear) 29 min. Prep time 0 min/panel Run time Punch Tooling Holes (after I&S) 10 min. Prep time 0.5 min/panel Run time How long will an 8 board order take? 20.5 minutes (I&S) min (Punch) = 31min total How much labor goes into an order? 31 min (above) + 29 min (Artwork) = 60 min total Drill choice Manual Drill 15 min. Prep time.08 min/hole 500 holes/board, 8 boards/panel 335 min. Total on 8 board order CNC Drill 240 min. Prep time.004 min/hole 500 holes/board, 8 boards/panel 256 min. Total on 8 board order

5 When do you use CNC drill over manual? (500)x = (500)x X = 5.9, approx 6 How many orders were done on CNC drill in September? Policy was for orders over 100 boards 9 orders, 4825 boards (from Ex. 4 or 2) Why only 9 orders? Capacity utilization = time used/time available 196.8/168 = 117% How are they over 100%? Need assumptions/explanations Router choice Manual Router 50 min. Prep time 1 min/board CNC Router 150 min. Prep time 1 min/board Break-even of 200 boards 50 + x = x

6 14 October Pre-Reading 2 Toshiba Case 2

7 14 October Pre-Reading Designing, Managing, and Improving Operations Toshiba Case Questions: Assuming the assembly line prototype in Exhibit 1 is implemented as shown in the exhibit, calculate the following quantities for that assembly line (Stations 1 to 10): Cycle Time 1258 seconds Adding totals from Exhibit 1 P. 6 - hardware tests run parallel for 3 units at a time, so items are done simultaneously on each line Work-in-Process (WIP) on the assembly line Work in process = (operating inventory goods in process + raw materials used during the period + direct labor during the period + factory overhead for period) - ending inventory How many can be running at the same time? 3 lines * 10 steps, 1 unit at each station at a time WIP = 10 machines on at a time Line speed Longest station takes 114 seconds Can t go faster than 1.44m/114sec = Direct labour content per notebook computer Subtract out idle time difference from station time and 114? exclude 208 seconds where computer is running? 1 computer/1258 seconds =.00079