Fig. 1 shows a simplified layout at a business that produces custom aluminium window frames. A frame moves only when the previous stage has been completed. ...
Question 1 Report
Fig. 1 shows a simplified layout at a business that produces custom aluminium window frames. A frame moves only when the previous stage has been completed. The manager is considering adding a second cutting machine because the cutting stage is slower than the other stages.
(a) Identify the bottleneck shown in Fig. 1. [1]
(b) Explain one likely effect of this bottleneck on the following stages. [2]
(c) Calculate the percentage increase in cutting capacity if output rises from 80 frames to 100 frames per day. [2]
(d) Explain one reason why quality checks should remain after capacity is increased. [2]
(e) Which production process is most likely shown by the layout? [1]
Answer Details
(a) The bottleneck is cutting lengths [1], because this stage is slower than the other stages.
(b) The later drilling, assembly and checking stages may have to wait for frames from cutting and be underused [1]. This delays production and reduces total output [1].
(c)
\[\text{Increase}=100-80=20\text{ frames per day}\]
\[\text{Percentage increase}=\frac{20}{80}\times100=25\%\]
The cutting capacity increases by 25% [2].
(d) Faster production may create defects or make defects less likely to be noticed [1]. Quality checks prevent faulty window frames reaching customers and protect the business's reputation [1].
(e) The layout is most likely flow production [1], since frames move through a fixed sequence of stages.
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