Math Problem Statement

The diagram describes a service process where customers go through either of two parallel three-step processes and then merge into a single line for two final steps. Capacities of each step are shown on the diagram. a. What is the current capacity of the entire system? b. If you could increase the capacity of only one operation through process improvement efforts, which operation would you select, how much additional capacity would you strive for, and what would the resulting capacity of the process be?

Solution

Let's break down and solve this problem in parts:

Part (a): What is the current capacity of the entire system?

Step 1: Identify the bottleneck in each path.

  • Path 1: Steps 1 → 2 → 3 → 7 → 8

    • Step 1: 11 units/hour
    • Step 2: 10 units/hour
    • Step 3: 19 units/hour
    • Step 7: 34 units/hour
    • Step 8: 34 units/hour
    • Bottleneck in Path 1: 10 units/hour (since Step 2 is the slowest step).
  • Path 2: Steps 4 → 5 → 6 → 7 → 8

    • Step 4: 12 units/hour
    • Step 5: 11 units/hour
    • Step 6: 7 units/hour
    • Step 7: 34 units/hour
    • Step 8: 34 units/hour
    • Bottleneck in Path 2: 7 units/hour (since Step 6 is the slowest step).

Step 2: The overall system capacity is determined by the sum of the capacities of the two parallel paths, taking into account their respective bottlenecks.

  • Path 1 Capacity: 10 units/hour
  • Path 2 Capacity: 7 units/hour

Since the two paths are parallel, the overall capacity is the sum of these bottlenecks: Overall capacity=10units/hour+7units/hour=17units/hour.\text{Overall capacity} = 10 \, \text{units/hour} + 7 \, \text{units/hour} = 17 \, \text{units/hour}.

Part (b): If you could increase the capacity of only one operation, which one would you choose?

Since Path 2 has the lower capacity (7 units/hour), improving the bottleneck in Path 2 would be the best choice to improve the system's overall capacity.

  • The bottleneck in Path 2 is Step 6 (7 units/hour).
  • If we could increase the capacity of Step 6, we would want it to match the capacity of the next limiting step, which is Step 5 (11 units/hour).

Thus, if we improve Step 6's capacity to 11 units/hour, the new system capacities would be:

  • Path 1: 10 units/hour (unchanged)
  • Path 2: 11 units/hour (new bottleneck after improvement).

The new overall system capacity would be: New overall capacity=10units/hour+11units/hour=21units/hour.\text{New overall capacity} = 10 \, \text{units/hour} + 11 \, \text{units/hour} = 21 \, \text{units/hour}.

Final Answers:

  • Current capacity: 17 units/hour
  • Operation to improve: Step 6
  • How much additional capacity to strive for: 4 units/hour (to increase from 7 units/hour to 11 units/hour)
  • Resulting capacity of the process: 21 units/hour

Let me know if you'd like further clarification on any part of the problem!

Here are some follow-up questions for practice:

  1. How would the system capacity change if Step 2's capacity were increased to 15 units/hour?
  2. What if Step 7 became the bottleneck with a capacity of 20 units/hour? What would be the new system capacity?
  3. If Step 4's capacity was reduced to 10 units/hour, how would the overall capacity be affected?
  4. What would happen if both Step 6 and Step 2 were improved by 5 units/hour each?
  5. If the two parallel paths had different demand rates, how would you adjust the capacities to balance them?

Tip: When dealing with parallel systems, always focus on improving the bottleneck first to maximize overall capacity.

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Math Problem Analysis

Mathematical Concepts

Operations Management
Parallel Processes
Bottleneck Analysis

Formulas

Overall system capacity = Sum of capacities of parallel paths' bottlenecks
New capacity = Path 1 capacity + Path 2 capacity

Theorems

Theory of Constraints
Bottleneck Principle

Suitable Grade Level

Undergraduate, Operations Management