Materials and packaging
Raw materials and packaging
Descpription
Item number
Type of product
Shelf life (days)
Lead time (days)
Annual usage
Unit of measure(uom)
Cost per uom
Annual cost
ABC
Frequency
Total cost to count
Total hours used
Chicken wings
1000
Raw material
7
5
3,000,000.00
lbs
$ 2.29
$ 6,870,000
Chicken tenders
1001
Raw material
10
5
7,000,000.00
lbs
$ 1.96
$ 13,720,000
Boneless dark meat
1002
Raw material
9
5
1,000,000.00
lbs
$ 1.56
$ 1,560,000
Brisket
1003
Raw material
14
5
8,000,000.00
lbs
$ 4.00
$ 32,000,000
Chopped beef
1004
Raw material
14
5
15,000,000.00
lbs
$ 3.50
$ 52,500,000
Ends and pieces
1005
Raw material
14
5
1,000,000.00
lbs
$ 4.75
$ 4,750,000
Sliced pork
1006
Raw material
12
5
1,000,000.00
lbs
$ 2.75
$ 2,750,000
Pulled pork
1007
Raw material
14
5
12,000,000.00
lbs
$ 3.40
$ 40,800,000
Ends and pieces
1008
Raw material
12
5
2,000,000.00
lbs
$ 4.50
$ 9,000,000
BBQ base 1
1009
Raw material
180
10
200,000.00
lbs
$ 0.25
$ 50,000
BBQ base 2
1010
Raw material
180
10
210,000.00
lbs
$ 0.25
$ 52,500
BBQ base 3
1011
Raw material
180
10
12,000.00
lbs
$ 0.25
$ 3,000
BBQ base 4
1012
Raw material
180
10
78,000.00
lbs
$ 0.35
$ 27,300
BBQ base 5
1013
Raw material
180
10
24,000.00
lbs
$ 0.35
$ 8,400
Spice 1
1014
Raw material
360
25
1,000.00
lbs
$ 0.15
$ 150
Spice 2
1015
Raw material
360
25
1,400.00
lbs
$ 0.16
$ 224
Spice 3
1016
Raw material
360
25
1,800.00
lbs
$ 0.31
$ 558
Spice 4
1017
Raw material
360
10
2,200.00
lbs
$ 0.33
$ 726
Spice 5
1018
Raw material
360
12
2,600.00
lbs
$ 0.35
$ 910
Spice 6
1019
Raw material
360
25
1,200.00
lbs
$ 0.37
$ 444
Spice 7
1020
Raw material
360
12
780.00
lbs
$ 0.39
$ 304
Spice 8
1021
Raw material
360
25
671.00
lbs
$ 0.41
$ 275
Spice 9
1022
Raw material
360
25
98.00
lbs
$ 0.43
$ 42
Spice 10
1023
Raw material
360
25
238.00
lbs
$ 0.45
$ 107
Spice 11
1024
Raw material
360
20
378.00
lbs
$ 0.65
$ 246
Spice 12
1025
Raw material
360
14
518.00
lbs
$ 0.99
$ 513
Spice 13
1026
Raw material
360
20
658.00
lbs
$ 1.33
$ 875
Spice 14
1027
Raw material
360
20
798.00
lbs
$ 1.67
$ 1,333
Spice 15
1028
Raw material
360
20
1,600.00
lbs
$ 2.01
$ 3,216
Spice 16
1029
Raw material
180
20
1,800.00
lbs
$ 2.35
$ 4,230
Spice 17
1030
Raw material
140
20
1,000.00
lbs
$ 2.69
$ 2,690
Spice 18
1031
Raw material
100
20
200.00
lbs
$ 3.03
$ 606
Spice 19
1032
Raw material
60
20
600.00
lbs
$ 3.37
$ 2,022
Spice 20
1033
Raw material
20
20
1,345.00
lbs
$ 27.98
$ 37,633
Tray 1
1034
Packaging
360
21
120,000,000.00
each
$ 0.25
$ 30,000,000
Tray 2
1035
Packaging
360
21
80,000,000.00
each
$ 0.25
$ 20,000,000
Tray 3
1036
Packaging
360
21
40,000,000.00
each
$ 0.25
$ 10,000,000
Carton 1
1037
Packaging
360
21
2,000,000.00
each
$ 0.15
166,666.67
$ 300,000
Carton 2
1038
Packaging
360
21
3,000,000.00
each
$ 0.15
250,000.00
$ 450,000
Carton 3
1039
Packaging
360
21
15,000,000.00
each
$ 0.15
1,250,000.00
$ 2,250,000
Carton 4
1040
Packaging
360
21
20,000,000.00
each
$ 0.15
1,666,666.67
$ 3,000,000
Carton 5
1041
Packaging
360
21
1,500,000.00
each
$ 0.15
125,000.00
$ 225,000
Carton 6
1042
Packaging
360
21
2,000,000.00
each
$ 0.15
166,666.67
$ 300,000
Carton 7
1043
Packaging
360
21
2,500,000.00
each
$ 0.15
208,333.33
$ 375,000
Carton 8
1044
Packaging
360
21
3,000,000.00
each
$ 0.15
250,000.00
$ 450,000
Carton 9
1045
Packaging
360
21
3,500,000.00
each
$ 0.15
291,666.67
$ 525,000
Carton 10
1046
Packaging
360
21
4,000,000.00
each
$ 0.15
333,333.33
$ 600,000
Carton 11
1047
Packaging
360
21
4,500,000.00
each
$ 0.15
375,000.00
$ 675,000
Carton 12
1048
Packaging
360
21
5,000,000.00
each
$ 0.15
416,666.67
$ 750,000
Carton 13
1049
Packaging
360
21
5,500,000.00
each
$ 0.15
458,333.33
$ 825,000
Carton 14
1050
Packaging
360
21
6,000,000.00
each
$ 0.15
500,000.00
$ 900,000
Carton 15
1051
Packaging
360
21
6,500,000.00
each
$ 0.15
541,666.67
$ 975,000
Carton 16
1052
Packaging
360
21
7,000,000.00
each
$ 0.15
583,333.33
$ 1,050,000
Carton 17
1053
Packaging
360
21
7,500,000.00
each
$ 0.20
625,000.00
$ 1,500,000
Carton 18
1054
Packaging
360
21
8,000,000.00
each
$ 0.20
666,666.67
$ 1,600,000
Carton 19
1055
Packaging
360
21
8,500,000.00
each
$ 0.20
708,333.33
$ 1,700,000
Carton 20
1056
Packaging
360
21
9,000,000.00
each
$ 0.20
750,000.00
$ 1,800,000
Carton 21
1057
Packaging
360
21
9,500,000.00
each
$ 0.20
791,666.67
$ 1,900,000
Carton 22
1058
Packaging
360
21
7,500,000.00
each
$ 0.20
625,000.00
$ 1,500,000
Carton 23
1059
Packaging
360
21
9,800,000.00
each
$ 0.20
816,666.67
$ 1,960,000
Carton 24
1060
Packaging
360
21
4,960,000.00
each
$ 0.20
413,333.33
$ 992,000
Carton 25
1061
Packaging
360
21
9,400,000.00
each
$ 0.20
783,333.33
$ 1,880,000
Carton 26
1062
Packaging
360
21
9,200,000.00
each
$ 0.20
766,666.67
$ 1,840,000
Carton 27
1063
Packaging
360
21
6,900,000.00
each
$ 0.20
575,000.00
$ 1,380,000
Carton 28
1064
Packaging
360
21
8,800,000.00
each
$ 0.20
733,333.33
$ 1,760,000
Carton 29
1065
Packaging
360
21
8,600,000.00
each
$ 0.20
716,666.67
$ 1,720,000
Carton 30
1066
Packaging
360
21
3,840,000.00
each
$ 0.20
320,000.00
$ 768,000
Carton 31
1067
Packaging
360
21
4,200,000.00
each
$ 0.20
350,000.00
$ 840,000
Carton 32
1068
Packaging
360
21
8,000,000.00
each
$ 0.20
666,666.67
$ 1,600,000
Carton 33
1069
Packaging
360
21
13,800,000.00
each
$ 0.25
1,150,000.00
$ 3,450,000
Carton 34
1070
Packaging
360
21
5,600,000.00
each
$ 0.25
466,666.67
$ 1,400,000
Carton 35
1071
Packaging
360
21
200,000.00
each
$ 0.25
16,666.67
$ 50,000
Carton 36
1072
Packaging
360
21
190,000.00
each
$ 0.25
15,833.33
$ 47,500
Carton 37
1073
Packaging
360
21
180,000.00
each
$ 0.25
15,000.00
$ 45,000
Carton 38
1074
Packaging
360
21
170,000.00
each
$ 0.25
14,166.67
$ 42,500
Carton 39
1075
Packaging
360
21
4,160,000.00
each
$ 0.25
346,666.67
$ 1,040,000
Carton 40
1076
Packaging
360
21
155,000.00
each
$ 0.25
12,916.67
$ 38,750
Carton 41
1077
Packaging
360
21
385,000.00
each
$ 0.25
32,083.33
$ 96,250
Carton 42
1078
Packaging
360
21
130,000.00
each
$ 0.25
10,833.33
$ 32,500
Carton 43
1079
Packaging
360
21
120,000.00
each
$ 0.25
10,000.00
$ 30,000
Carton 44
1080
Packaging
360
21
110,000.00
each
$ 0.25
9,166.67
$ 27,500
Carton 45
1081
Packaging
360
21
100,000.00
each
$ 0.25
8,333.33
$ 25,000
Shipping case 1
1082
Packaging
120
5
3,000,000.00
each
$ 0.75
$ 2,250,000
Shipping case 2
1083
Packaging
120
5
4,000,000.00
each
$ 0.75
$ 3,000,000
Shipping case 3
1084
Packaging
120
5
2,500,000.00
each
$ 0.75
$ 1,875,000
Shipping case 4
1085
Packaging
120
5
9,000,000.00
each
$ 0.75
$ 6,750,000
Shipping case 5
1086
Packaging
120
5
900,000.00
each
$ 0.75
$ 675,000
Shipping case 6
1087
Packaging
120
5
600,000.00
each
$ 1.25
$ 750,000
Film 1
1088
Packaging
360
21
200,000,000.00
each print
$ 0.05
$ 10,000,000
Film 2
1089
Packaging
360
21
35,000,000.00
each print
$ 0.05
$ 1,750,000
Film 3
1090
Packaging
360
21
5,000,000.00
each print
$ 0.05
$ 250,000
Vegetable 1
1091
Raw material
120
30
30,000,000.00
lbs
$ 0.27
$ 8,100,000
Vegetable 2
1092
Raw material
120
30
18,000,000.00
lbs
$ 0.47
$ 8,460,000
Vegetable 3
1093
Raw material
120
30
5,000,000.00
lbs
$ 0.67
$ 3,350,000
Vegetable 4
1094
Raw material
120
30
6,000,000.00
lbs
$ 0.87
$ 5,220,000
Vegetable 5
1095
Raw material
120
60
1,000,000.00
lbs
$ 1.07
$ 1,070,000
Frozen beef
1096
Raw material
180
15
1,400,000.00
lbs
$ 1.65
$ 2,310,000
Fresh beef
1097
Raw material
14
15
300,000.00
lbs
$ 1.79
$ 537,000
Deboned chicken
1098
Raw material
10
15
3,000,000.00
lbs
$ 1.98
$ 5,940,000
Labels (shipping) 1
1099
Packaging
180
14
1,000,000.00
each
$ 0.10
$ 100,000
Labels (shipping) 2
1100
Packaging
180
14
1,000,000.00
each
$ 0.10
$ 100,000
Labels (shipping) 3
1101
Packaging
180
14
2,500,000.00
each
$ 0.10
$ 250,000
Labels (shipping) 4
1102
Packaging
180
14
1,000,000.00
each
$ 0.10
$ 100,000
Labels (shipping) 5
1103
Packaging
180
14
720,000.00
each
$ 0.10
$ 72,000
Labels (shipping) 6
1104
Packaging
180
14
50,000.00
each
$ 0.10
$ 5,000
Labels (shipping) 7
1105
Packaging
180
14
10,000.00
each
$ 0.10
$ 1,000
Labels (shipping) 8
1106
Packaging
180
14
1,000,000.00
each
$ 0.10
$ 100,000
Labels (shipping) 9
1107
Packaging
180
14
1,000,000.00
each
$ 0.10
$ 100,000
Labels (shipping) 10
1108
Packaging
180
14
1,000,000.00
each
$ 0.10
$ 100,000
Labels work in process 1
1109
Packaging
180
14
5,000,000.00
each
$ 0.45
$ 2,250,000
Labels work in process 2
1110
Packaging
180
14
2,500,000.00
each
$ 0.35
$ 875,000
Dry food ingredient 1
1111
Raw material
180
5
350,000.00
lbs
$ 0.50
$ 175,000
Dry food ingredient 2
1112
Raw material
180
7
375,000.00
lbs
$ 0.52
$ 195,000
Dry food ingredient 3
1113
Raw material
180
9
400,000.00
lbs
$ 0.54
$ 216,000
Dry food ingredient 4
1114
Raw material
180
11
425,000.00
lbs
$ 0.56
$ 238,000
Dry food ingredient 5
1115
Raw material
180
13
450,000.00
lbs
$ 0.58
$ 261,000
Dry food ingredient 6
1116
Raw material
180
15
475,000.00
lbs
$ 0.60
$ 285,000
Dry food ingredient 7
1117
Raw material
180
17
500,000.00
lbs
$ 0.62
$ 310,000
Dry food ingredient 8
1118
Raw material
180
19
525,000.00
lbs
$ 0.64
$ 336,000
Dry food ingredient 9
1119
Raw material
200
21
550,000.00
lbs
$ 0.66
$ 363,000
Dry food ingredient 10
1120
Raw material
200
23
575,000.00
lbs
$ 0.68
$ 391,000
Dry food ingredient 11
1121
Raw material
200
25
600,000.00
lbs
$ 0.70
$ 420,000
Dry food ingredient 12
1122
Raw material
200
27
625,000.00
lbs
$ 0.66
$ 412,500
Dry food ingredient 13
1123
Raw material
200
29
1,650,000.00
lbs
$ 0.62
$ 1,023,000
Dry food ingredient 14
1124
Raw material
200
31
1,675,000.00
lbs
$ 0.58
$ 971,500
Dry food ingredient 15
1125
Raw material
200
33
700,000.00
lbs
$ 0.54
$ 378,000
Dry food ingredient 16
1126
Raw material
240
35
725,000.00
lbs
$ 0.50
$ 362,500
Dry food ingredient 17
1127
Raw material
240
37
750,000.00
lbs
$ 0.46
$ 345,000
Dry food ingredient 18
1128
Raw material
240
39
775,000.00
lbs
$ 0.42
$ 325,500
Dry food ingredient 19
1129
Raw material
240
41
800,000.00
lbs
$ 0.38
$ 304,000
Dry food ingredient 20
1130
Raw material
240
43
825,000.00
lbs
$ 0.34
$ 280,500
Dry food ingredient 21
1131
Raw material
225
45
850,000.00
lbs
$ 0.30
$ 255,000
Dry food ingredient 22
1132
Raw material
210
47
875,000.00
lbs
$ 0.26
$ 227,500
Dry food ingredient 23
1133
Raw material
195
49
900,000.00
lbs
$ 0.22
$ 198,000
Dry food ingredient 24
1134
Raw material
180
51
925,000.00
lbs
$ 0.18
$ 166,500
Dry food ingredient 25
1135
Raw material
165
53
950,000.00
lbs
$ 0.25
$ 237,500
Dry food ingredient 26
1136
Raw material
150
55
975,000.00
lbs
$ 0.35
$ 341,250
Dry food ingredient 27
1137
Raw material
130
57
10,000,000.00
lbs
$ 0.45
$ 4,500,000
Dry food ingredient 28
1138
Raw material
110
59
8,000,000.00
lbs
$ 0.55
$ 4,400,000
Dry food ingredient 29
1139
Raw material
90
61
6,000,000.00
lbs
$ 0.65
$ 3,900,000
Dry food ingredient 30
1140
Raw material
70
63
4,000,000.00
lbs
$ 0.75
$ 3,000,000
Dry food ingredient 31
1141
Raw material
50
65
2,000,000.00
lbs
$ 0.75
$ 1,500,000
Dry food ingredient 32
1142
Raw material
30
67
1,500,000.00
lbs
$ 0.75
$ 1,125,000
Total column F
– 0
Total columns
FTE
– 0
Instructions ABC Cycle count
All yellow boxes on Materials and packaging tab must be populated using an Excel formula. Usiing material from Skills Development in the Final Assignment tab you will sort the items as needed and develop a workable ABC analysis and a cycle count plan. Column K will be the total cost on an annual basis. It is your choice to conduct the ABC anlaysis using either total annual usage in pounds or unit of measure, total annual cost, or any other method as referenced in the powerpoint. Column L will have a designation in each cell either A, B, C. Column M will be the frequency that the counts occur. A items should be less than 8 days (weekly). B items should be 30 to 60 days, and C items 90 to 180 days. You may choose to make all A items the same time (recommended) or some combination of frequency as long as it is within the paramenters stated above. All B items and C items will follow this same pattern. Example and Exception: If you decide to count all A items weekly but identify one item as problematic and wish to count it more frequently that is allowable. Column N is the cost to count. Assume each count takes 27 minutes to complete using one employee that is paid $18.75 per hour with a fully loaded labor rate with fringes of $25.50 per hour. The sum of column N will be the total annual cost. The sum of column M will be the total number of counts needed annually. Column O will be the time in hours to count each item and will be needed to calculate final cost. The rationale and decisions that go into your analysis will be included in the Executive Summary and should include a chart, table or graph similar to the examples in the powerpoint The Finance and accounting Departments of your company remind you a rule exists that states that every item wheter a material or a finished good must be counted at least twice per year. The reason you are conducting the ABC analysis is the plant has an issue with running out of material and either making a mid shift unplanned changeover or losses the last 15 to 90 minutes of a shift as the changeover cannot be accomplished in a manner that makes it worthwhile to hold the crew. Estimates are that up to 2.5% of run time is lost to short shifts and unplanned changes. Studies suggest than 1% could be eliminated with a rodust cycle count program. Approximately 1% is related to changeovers that cannot be avoided and .5% is related to supplier issues. You are permitted to recommend the cycle count program that just meets the company requirements (which is already in place) and you will get 70% on this problem as long as you
Instructions SKU rationalizatio
H
The goal of this portion of the assignment is to conduct an SKU rationalization to address the capacity issue from the Statement of Facts document in Content/Material for Final Project/Problems in D2L. There are three tabs in this workbook that will be used. Finished goods Before, FG after productivity improve, and FG after SKU. You will need to conduct an analysis of the Finished goods Before and determine which if any of the SKUs are candidates to be eliminated. I would sort the data provided by cases from highest to lowest before starting on the rationalization. All the yellow boxes on Finished goods Before must be populated. Highlight the SKUs you are considering for elimination in red. On the FG after productivity improve tab you will adjust the numbers in columns D and H to reflect the increased productivity from the results of your ABC analysis (reduces downtime 1.5%) and carton machine downtime reduction (1%) project. All yellow boxes must be populated. Again I would sort by Cases. Totals for Cases and Productivity in Finished Goods After should all be higher than the original numbers. On the FG after SKU tab:To remove the skus from the final calculations place a 0 in the appropriate rows of Column F. For example if you choose to eliminate FG 1080a and FG 1081a you would place a 0 in cells F46 and F 47. Hint: These are the first two I would eliminate. By removing SKUS from the calculation you will have additional cases available to add to some of the remaining skus to get back tp 2000 shifts. Your findings and conclusions will be summarized in the executive summary. All yellow boxes must be populated.
Finished goods Before
Finished goods Before
SKU
Profit per case (Total Revenue- Total Cost)
Cases
Profit before taxes
avg cases per line hour
line hrs per case
Required line hours
Required shifts
number of lines
Shifts per day
Days per week
Weeks per year
minutes per line shift
Shifts per year
FG 1037
$ 0.16
58,000
1160
0.000862
FG 1038
$ 0.20
74,000
1200
0.000833
FG 1039
$ 0.20
1,620,000
1333
0.000750
FG 1040
$ 0.20
2,100,000
1333
0.000750
FG 1041
$ 0.16
55,000
1150
0.000870
FG 1042
$ 0.16
62,000
1140
0.000877
FG 1043
$ 0.24
66,000
1180
0.000847
FG 1044a
$ 0.16
71,905
980
0.001020
FG 1045
$ 0.20
78,000
1220
0.000820
FG 1046
$ 0.20
90,000
1220
0.000820
FG 1047
$ 0.20
98,000
1220
0.000820
FG 1048
$ 0.12
106,000
1220
0.000820
FG 1049a
$ 0.20
475,000
980
0.001020
FG 1050
$ 0.20
500,000
1240
0.000806
FG 1051
$ 0.20
541,666
1250
0.000800
FG 1052
$ 0.20
583,333
1270
0.000787
FG 1053
$ 0.23
525,000
1300
0.000769
FG 1054
$ 0.20
620,000
1310
0.000763
FG 1055
$ 0.19
700,000
1260
0.000794
FG 1056
$ 0.20
550,000
1325
0.000755
FG 1057a
$ 0.20
601,000
1275
0.000784
FG 1058
$ 0.20
625,000
1280
0.000781
FG 1059
$ 0.23
1,516,680
1100
0.000909
FG 1060
$ 0.20
102,000
1220
0.000820
FG 1061
$ 0.20
1,415,600
1325
0.000755
FG 1062
$ 0.26
850,000
1325
0.000755
FG 1063
$ 0.20
575,000
1260
0.000794
FG 1064
$ 0.20
739,000
1325
0.000755
FG 1065
$ 0.20
718,000
1240
0.000806
FG 1066a
$ 0.15
86,000
1220
0.000820
FG 1067
$ 0.20
94,000
1220
0.000820
FG 1068
$ 0.21
535,000
1300
0.000769
FG 1069
$ 0.20
1,333,000
1333
0.000750
FG 1070
$ 0.20
466,670
1230
0.000813
FG 1071
$ 0.16
48,000
1145
0.000873
FG 1072a
$ 0.17
19,000
1000
0.001000
FG 1073a
$ 0.18
16,980
925
0.001081
FG 1074a
$ 0.18
15,570
990
0.001010
FG 1075
$ 0.20
82,000
1220
0.000820
FG 1076a
$ 0.18
14,212
1000
0.001000
FG 1077
$ 0.16
50,000
1150
0.000870
FG 1078a
$ 0.18
10,900
1000
0.001000
FG 1079a
$ 0.18
10,200
780
0.001282
FG 1080a
$ 0.16
9,300
770
0.001299
FG 1081a
$ 0.14
8,670
650.0
0.001538
Total cases
18,915,686
Totals
Productivity
Average cases/line hr
Average profit per case
FG after productivity improve
SKU
Profit per case (Total Revenue- Total Cost)
Cases Before
Cases After ABC and Downtime projects
Profit after
avg cases per line hour before
avg cases per line hour after ABC and Downtime project
Required line hours
Required shifts
FG 1037
$ 0.16
58,000
1160
FG 1038
$ 0.20
74,000
1200
FG 1039
$ 0.20
1,620,000
1333
FG 1040
$ 0.20
2,100,000
1333
FG 1041
$ 0.16
55,000
1150
FG 1042
$ 0.16
62,000
1140
FG 1043
$ 0.24
66,000
1180
FG 1044a
$ 0.16
71,905
980
FG 1045
$ 0.20
78,000
1220
FG 1046
$ 0.20
90,000
1220
FG 1047
$ 0.20
98,000
1220
FG 1048
$ 0.12
106,000
1220
FG 1049a
$ 0.20
475,000
980
FG 1050
$ 0.20
500,000
1240
FG 1051
$ 0.20
541,666
1250
FG 1052
$ 0.20
583,333
1270
FG 1053
$ 0.23
525,000
1300
FG 1054
$ 0.20
620,000
1310
FG 1055
$ 0.19
700,000
1260
FG 1056
$ 0.20
550,000
1325
FG 1057a
$ 0.20
601,000
1275
FG 1058
$ 0.20
625,000
1280
FG 1059
$ 0.23
1,516,680
1100
FG 1060
$ 0.20
102,000
1220
FG 1061
$ 0.20
1,415,600
1325
FG 1062
$ 0.26
850,000
1325
FG 1063
$ 0.20
575,000
1260
FG 1064
$ 0.20
739,000
1325
FG 1065
$ 0.20
718,000
1240
FG 1066a
$ 0.16
86,000
1220
FG 1067
$ 0.20
94,000
1220
FG 1068
$ 0.22
535,000
1300
FG 1069
$ 0.20
1,333,000
1333
FG 1070
$ 0.20
466,670
1230
FG 1071
$ 0.16
48,000
1145
FG 1072a
$ 0.17
19,000
1000
FG 1073a
$ 0.18
16,980
925
FG 1074a
$ 0.18
15,570
990
FG 1075
$ 0.20
82,000
1220
FG 1076a
$ 0.19
14,212
1000
FG 1077
$ 0.16
50,000
1150
FG 1078a
$ 0.19
10,900
1000
FG 1079a
$ 0.18
10,200
780
FG 1080a
$ 0.16
9,300
770
FG 1081a
$ 0.14
8,670
650
Totals
18,915,686
Totals
Productivity
Average cases/line hr
% change in cases after
% change in cases per hour after
% change in shifts after (should be close to no change)
change in profit
FG after SKU
SKU
Profit per case (Total Revenue- Total Cost)
Cases Before
Cases After ABC and Downtime Project
Cases After Sku
Profit after sku rationalization
avg cases per line hour before
avg cases per line hour after ABC and Downtime project
Required line hours
Required shifts
FG 1037
$ 0.16
58,000
– 0
1160
0
FG 1038
$ 0.21
74,000
– 0
1200
0
FG 1039
$ 0.21
1,620,000
– 0
1333
0
FG 1040
$ 0.21
2,100,000
– 0
1333
0
FG 1041
$ 0.16
55,000
– 0
1150
0
FG 1042
$ 0.16
62,000
– 0
1140
0
FG 1043
$ 0.25
66,000
– 0
1180
0
FG 1044a
$ 0.16
71,905
– 0
980
0
FG 1045
$ 0.21
78,000
– 0
1220
0
FG 1046
$ 0.21
90,000
– 0
1220
0
FG 1047
$ 0.21
98,000
– 0
1220
0
FG 1048
$ 0.12
106,000
– 0
1220
0
FG 1049a
$ 0.21
475,000
– 0
980
0
FG 1050
$ 0.21
500,000
– 0
1240
0
FG 1051
$ 0.21
541,666
– 0
1250
0
FG 1052
$ 0.21
583,333
– 0
1270
0
FG 1053
$ 0.23
525,000
– 0
1300
0
FG 1054
$ 0.21
620,000
– 0
1310
0
FG 1055
$ 0.19
700,000
– 0
1260
0
FG 1056
$ 0.20
550,000
– 0
1325
0
FG 1057a
$ 0.20
601,000
– 0
1275
0
FG 1058
$ 0.21
625,000
– 0
1280
0
FG 1059
$ 0.24
1,516,680
– 0
1100
0
FG 1060
$ 0.21
102,000
– 0
1220
0
FG 1061
$ 0.21
1,415,600
– 0
1325
0
FG 1062
$ 0.26
850,000
– 0
1325
0
FG 1063
$ 0.21
575,000
– 0
1260
0
FG 1064
$ 0.21
739,000
– 0
1325
0
FG 1065
$ 0.21
718,000
– 0
1240
0
FG 1066a
$ 0.16
86,000
– 0
1220
0
FG 1067
$ 0.21
94,000
– 0
1220
0
FG 1068
$ 0.22
535,000
– 0
1300
0
FG 1069
$ 0.21
1,333,000
– 0
1333
0
FG 1070
$ 0.21
466,670
– 0
1230
0
FG 1071
$ 0.16
48,000
– 0
1145
0
FG 1072a
$ 0.18
19,000
– 0
1000
0
FG 1073a
$ 0.18
16,980
– 0
925
0
FG 1074a
$ 0.19
15,570
– 0
990
0
FG 1075
$ 0.21
82,000
– 0
1220
0
FG 1076a
$ 0.19
14,212
– 0
1000
0
FG 1077
$ 0.16
50,000
– 0
1150
0
FG 1078a
$ 0.19
10,900
– 0
1000
0
FG 1079a
$ 0.18
10,200
– 0
780
0
FG 1080a
$ 0.16
9,300
– 0
770
0
FG 1081a
$ 0.14
8,670
– 0
650
0
Totals
Totals
Productivity
Average cases/line hr
% change in cases after
% change in cases per hour after
% change in shifts after (should be close to no change)
change in profit
SHOW MORE…
Homework 7
1. The following activities are part of a project to be scheduled using CPM:
Activity
Immediate Predecessor
Time (Weeks)
A
–
6
B
A
3
C
A
7
D
C
2
E
B, D
4
F
D
3
G
E, F
7
a. Draw the network.
b. What is the critical path?
c. How many weeks will it take to complete the project?
d. How much slack does activity B have?
2. Schedule the following activities using CPM:
Activity
Immediate Predecessor
Time (Weeks)
A
–
1
B
A
4
C
A
3
D
B
2
E
C. D
5
F
D
2
G
F
2
H
E, G
3
a. Draw the network.
b. What is the critical path?
c. How many weeks will it take to complete the project?
d. Which activities have slack, and how much?
3. Following are the process flow sequences for three products: A, B, and C. There are two bottleneck operationson the first leg and fourth legmarked with an X. Boxes represent processes, which may be either machine or manual. Suggest the location of the drum, buffer, and ropes.
4. The accompanying figure shows a production network model with the parts and processing sequences. State clearly on the figure (1) where you would place inventory; (2) where you would perform inspection; and (3) where you would emphasize high-quality output.
5. The following production flow shows Parts E, I, and N; Subassembly O; and the final assembly for Product P.
A to B to C to D to E
F to G to H to I
J to K to L to M to N
E and I to O
N and O to P
B involves a bottleneck operation, and M involves a CCR.
a. Draw the process flow.
b. Where would you locate buffer inventories?
c. Where would you place inspection points?
d. Where would you stress the importance of quality production?
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