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MBA Company produces backpacks. The process requires 9 tasks to complete one batch, with the following allotted time per task: 7 min, 4 min, 9 min, 2 min, 8 min, 6 min, 4 min, 5 min, and 5 min respectively. The employees work for 40 hours per week, given 5 days to work in a week. The company needs to deliver 100 backpacks to their licensed distributors every week.

Based on the above data, answer the following questions:

1. How many units will be produced per day?
2. What is the cycle time?
3. How many workstations are needed?
4. How many days are needed to produce the 100 backpacks?

Answer :

1. The number of units produced per day is 20 backpacks.

2. The cycle time is 21 minutes per backpack.

3. Six workstations are needed.

4. Five days are needed to produce the 100 backpacks.

To calculate the number of units produced per day, we need to determine the total production time available per day. Since the employees work for 40 hours per week, with 5 days to work, we have 40 hours divided by 5 days, which gives us 8 hours per day. Converting this to minutes, we have 8 hours multiplied by 60 minutes, resulting in 480 minutes per day.

Dividing this by the cycle time of 21 minutes per backpack, we get 22.86 backpacks per day. Since we cannot produce a fraction of a backpack, the number of units produced per day is 20 backpacks.

The cycle time is the time required to complete one unit of the product. In this case, the total time for all the tasks is 7 + 4 + 9 + 2 + 8 + 6 + 4 + 5 + 5 = 50 minutes.

Since we need to produce 20 backpacks per day, the cycle time is calculated as 50 minutes divided by 20 backpacks, resulting in a cycle time of 2.5 minutes per backpack. Converting this to minutes, we have a cycle time of 21 minutes per backpack.

To determine the number of workstations needed, we divide the total production time per backpack (50 minutes) by the cycle time (21 minutes). This gives us approximately 2.38 workstations. Since we cannot have a fraction of a workstation, we round it up to the nearest whole number. Therefore, we need six workstations to complete the production process.

Since we need to produce 100 backpacks and the production rate is 20 backpacks per day, we divide 100 by 20, which equals 5 days. Therefore, it would take five days to produce the 100 backpacks.

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