Problem 1

1. There are six stages in a semi-automated process and the relevant details are given in
Table below.
Process Step Process Time (Seconds) Equipment Labour
Step 1 20 Machine A Worker A
Step 2 45 Machine B No Workers
Step 3 10 Machine C Worker A
Step 4 20 No Resources No Worker
Step 5 5 Machine D Worker B
Step 6 10 No Resources Worker B
Use this information to answer the following questions:
a. How long will it take to respond to an arriving order (Seconds)?

b. Estimate the capacities (Units per hour) at each step.

c. What is the daily production if the system works for 8 hours every day (number of
Units)?

d. What is the utilisation (in %) of each resource in the system?

e. If we need to increase the production by 25 percent, what should we do?

Problem 2
a. Ram runs a small roti shop. People can place their order over the phone and come and
collect the roti. Orders are taken for a standard pack of 5 rotis. The entire process is done
in batches of 5 rotis only. Roti making and delivery has five steps. Preparing the dough (3
minutes), rolling (5 minutes), heating (4 minutes), packing (2 minutes), billing and cash
(1 minute). Given this process, answer the following:
i. Prepare a process flow chart and identify the bottleneck for the shop.
ii. If somebody calls Ram over the phone, when should he ask them to come?
iii. If Ram keeps his shop open for 4 hours, how many rotis can he hope to make?