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Quality and Capacity Planning ProblemsAfter reading Chapters 3 and 4 in your Operations Management: Processes and Supply Chains text, 1. select one question from the "Statistical Process Control" sec
Quality and Capacity Planning Problems
After reading Chapters 3 and 4 in your Operations Management: Processes and Supply Chains text,
1. select one question from the "Statistical Process Control" section on pages 124–129,
3. The Canine Gourmet Company produces delicious dog treats for canines with discriminating tastes. Management wants the box-filling line to be set so that the process average weight per packet is 45 grams. To make sure that the process is in control, an inspector at the end of the filling line periodically selects a random box of 10 packets and weighs each packet. When the process is in control, the range in the weight of each sample has averaged 6 grams.
· a. Design an R- and an ¯x-chart for this process.
· b. The results from the last 5 samples of 10 packets are
Sample
¯x
R
1
44
9
2
40
2
3
46
5
4
39
8
5
48
3
Is the process in control? Explain.
2. one question from the "Process Capability" section on pages 129–131.
Process Capability
· 24. The production manager at Sunny Soda, Inc., is interested in tracking the quality of the company’s 12-ounce bottle filling line. The bottles must be filled within the tolerances set for this product because the dietary information on the label shows 12 ounces as the serving size. The design standard for the product calls for a fill level of 12.00 ± 0.10 ounces. The manager collected the following sample data (in fluid ounces per bottle) on the production process:
OBSERVATION
Sample
1
2
3
4
1
12.00
11.97
12.10
12.08
2
11.91
11.94
12.10
11.96
3
11.89
12.02
11.97
11.99
4
12.10
12.09
12.05
11.95
5
12.08
11.92
12.12
12.05
6
11.94
11.98
12.06
12.08
7
12.09
12.00
12.00
12.03
8
12.01
12.04
11.99
11.95
9
12.00
11.96
11.97
12.03
10
11.92
11.94
12.09
12.00
11
11.91
11.99
12.05
12.10
12
12.01
12.00
12.06
11.97
13
11.98
11.99
12.06
12.03
14
12.02
12.00
12.05
11.95
15
12.00
12.05
12.01
11.97
o a. Are the process average and range in statistical control?
o b. Is the process capable of meeting the design standard at four-sigma quality? Explain.
and one question from Chapter 4, pages 150–156.
7. Macon Controls produces three different types of control units used to protect industrial equipment from overheating. Each of these units must be processed by a machine that Macon considers to be their process bottleneck. The plant operates on two 8-hour shifts, 5 days per week, 52 weeks per year. Table 4.2 provides the time standards at the bottleneck, lot sizes, and demand forecasts for the three units. Because of demand uncertainties, the operations manager obtained three demand forecasts (pessimistic, expected, and optimistic). The manager believes that a 20 percent capacity cushion is best.
TABLE 4.2 CAPACITY INFORMATION FOR MACON CONTROLS TIME STANDARD DEMAND FORECAST Component Processing (hr/unit) Setup (hr/lot) Lot Size (units/lot) Pessimistic Expected Optimistic A 0.05 1.0 60 15,000 18,000 25,000 B 0.20 4.5 80 10,000 13,000 17,000 C 0.05 8.2 120 17,000 25,000 40,000 a. How many machines are required to meet minimum (pessimistic) demand, expected demand, and maximum (optimistic) demand? b. How many machines are required if the operations manager decides to double lot sizes? c. If the operations manager has three machines and believes that the plant can reduce setup time by 20 percent through process improvement initiatives, does that plant have adequate capacity to meet all demand scenarios without increasing lot sizes?
Solve the three problems and post your answers in the discussion area.
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