Solution:
Given,
Setup time of machine= 150 min
0.0075 min/pc.
1 order =10,000 pcs.
1 day= 2 shifts X 450 min each
1 order per batch
10000 pcs per batch before setup required again
(150 min setup time) –> (75 min run time for 10000 pcs) –> (150 min setup time) –> (75 min run time for 10000 pcs) = 450 mins
Total for shift 1 = 20,000 pcs
Similarly, for Shift 2, total production cap = 20,000 pcs
So, total capacity in this case is 40,000 pieces/day
3 orders per batch
30,000 pcs per batch before setup required again
Shift 1: (150 min setup time) –> (225 min run time for 30,000 pcs) –> (75 min setup time) = 450 mins
Shift 2: (75 min setup time) –> (225 min run time for 30,000 pcs) –> (150 min setup time) = 450 mins
So, total capacity in this case is 60,000 pieces/day
All orders can be combined in one batch
No cap on number of orders in a batch
Shift 1: (150 min setup time) –> (300 min run time for 40,000 pcs) = 450 min
Shift 2: (450 min run time for 60,000 pcs) = 450 min
So, total capacity in this case is 100,000 pieces/day
From (i) to (ii) there is 50% increase in capacity
From (ii) to (iii) there is 66.67% increase in capacity
