Carol Cagle has a repetitive manufacturing plant producing trailer hitches in Arlington, Texas. The plant has an average inventory turnover of only 12 times per year. She has therefore determined that she will reduce her component lot sizes. She has developed the following data for one component, the safety chain clip:

Annual demand $=31,200$ units

Daily demand $=120$ units

Daily production (in 8 hours) $=960$ units

Desired lot size ( 1 hour of production $)=120$ units

Holding cost per unit per year $=$ $\$12$

Setup labor cost per hour $=\$ 20$

How many minutes of setup time should she have her plant manager aim for regarding this component?

Given the following information about a product at Michael Gibson's firm, what is the appropriate setup time? Annual demand = 39,000 units Daily demand = 150 units Daily production = 1,000 units Desired lot size = 150 units Holding cost per unit per year = $10 Setup labor cost per hour =$40

Pauline Found Manufacturing, Inc., is moving to kanbans to support its telephone switching-board assembly lines. Determine the size of the kanban for subassemblies and the number of kanbans needed.

Setup cost $=\$ 30$

Annual holding cost $=\$ 120$ per subassembly

Daily production $=20$ subassemblies

Annual usage $=2,500(50$ weeks $\times 5$ days each $\times$ daily usage of 10 subassemblies)

Lead time $=16$ days

Safety stock $=4$ days $^{\prime}$ production of subassemblies

Ron Satterfield's excavation company uses both Gantt scheduling charts and Gantt load charts.

Today, which is the end of day 7 , Ron is reviewing the Gantt chart depicting these schedules:

• Job #151 was scheduled to begin on day 3 and to take 6 days. As of now, it is 1 day ahead of schedule.
• Job #177 was scheduled to begin on day 1 and take 4 days. It is currently on time.
• Job #179 was scheduled to start on day 7 and take 2 days. It actually got started on day 6 and is progressing according to plan.
• Job #211 was scheduled to begin on day 5 , but missing equipment delayed it until day 6 . It is progressing as expected and should take 3 days.
• Job #215 was scheduled to begin on day 4 and take 5 days. It got started on time but has since fallen behind 2 days . Draw the Gantt scheduling chart for the activities above.

Tej Dhakar's company wants to establish kanbans to feed a newly established work cell. The following data have been provided. How many kanbans are needed?

The Beta II computer's electronic processing unit contains 50 components in series. The average reliability of each component is 99.0%. Using given figure, determine the overall reliability of the processing unit.

Rick Wing has a repetitive manufacturing plant producing automobile steering wheels. Use the following data to prepare for a reduced lot size. The firm uses a work year of 305 days.

What is the setup time, based on $\$ 40$ per hour setup labor?

Discount-Mart, a major East Coast retailer, wants to determine the economic order quantity for its halogen lamps. It currently buys all halogen lamps from Specialty Lighting Manufacturers in Atlanta. Annual demand is 2,000 lamps, ordering cost per order is $30, and annual carrying cost per lamp is$12. How many orders should Discount-Mart place with Specialty Lighting per year?

Describe briefly what an automatic identification system (AIS) is and how service organizations could use AIS to increase productivity and at the same time increase the variety of services offered,

Pauline Found Manufacturing, Inc., is moving to kanbans to support its telephone switching-board assembly lines. Determine the size of the kanban for subassemblies and the number of kanbans needed. Setup cost = $30 Annual holding cost =$120 per subassembly Daily production = 20 subassemblies Annual usage = 2,500 (

$$\text{50 weeks}\times\text{5 days each}\times\text{daily usage of 10 subassemblies}$$

) Lead time = 16 days Safety stock = 4 days’ production of subassemblies

As the production planner for Xiangling Hu Products, Inc., you have been given a bill of material for a bracket that is made up of a base, two springs, and four clamps. The base is assembled from one clamp and two housings. Each clamp has one handle and one casting. Each housing has two bearings and one shaft. There is no inventory on hand.

Design a product structure noting the quantities for each item and show the low-level coding.

You have developed the following simple product structure of items needed for your gift bag for a rush party for prospective pledges in your organization. You forecast 200 attendees. Assume that there is no inventory on hand of any of the items. Explode the bill of material. (Subscripts indicate the number of units required.)

Maggie Moylan Motorcycle Corp. uses kanbans to support its transmission assembly line. Determine the size of the kanban for the mainshaft assembly and the number of kanbans needed. Setup cost = $20 Annual holding cost of mainshaft assembly =$250 per unit Daily production = 300 mainshafts Annual usage = 20,000(

$$\text{50 weeks}\times\text{5 days each}\times\text{daily usage of 80 subassemblies}$$

)Lead time $=3$ days Safety stock =

$$\dfrac{1}{2}$$

day's production of mainshafts

A Northeast Airlines gate agent, Chip Gilliken, gives out seat assignments to ticketed passengers. He takes an average of 50 seconds per passenger and is rated $110 \%$ in performance. How long should a typical agent be expected to take to make seat assignments?