NCC Skill Building

206562 Production Planning and Inventory Control ( IE)

Pornpunsa Wuttisanwattana
Every day trucks carrying wet berries arrive uniformly over an 8 hour interval ( between 8 am and 4 pm) to a berry arrival rate is 1,200 bbls per hour. The berries are dumped into holding bins with a storage capacity of 3,600 bbls, and trucks start queueing up as soon as the bins are full. The plant starts to process berries, according to the FIFO ( first-in-first-out) protocol, sharply at 12 noon at the rate of 800 bbls per hour, Berry processing continues till all berries that arrived are processed. The scenario described above repeats itself every day. 1. Draw an inventory buildup diagram that shows total berry inventory in the system ( bins and trucks) starting at 8 am and ending at 8 am the following day.

Buildup Inventory
7000 6400 6000

5000
4000 3000 2000 1000 0

4800

3200

0 8:00 Truck Start

12:00 Plant Start

16:00 Truck Stop

20:00 Plant Stop

0 24:00

0
8:00

The plant stop working at 20:00. However, wet berries cannot be stored overnight. So, during 20:00 to 24:00 will be Overtime working 2. At what time of the day ( Clock time) do trucks start to queue up? The truck will queue up when the barrels of berries is reached the capacity of bins -- 3,600 bbls. The wet berries arrive at the rate of 1200 bbl/hr Therefore, it will take Ans The truck will begin queueing at 11:00. 3. At what time of the day ( clock time) can the last truck leave? The last truck can leave when all berries are stored only in the bins or when the inventory of berries goes down to 3600 bbls. 6400 bbls 3600 bbls = 2 hrs 800 bbl/hr Ans Therefore, the last truck can leave at 16:00 + 3.5 = 19:30 O'clock 4. What is the average ( long term) inventory of berries in the holding bins? Time 8:00 - 11:00 11:00 - 19:30 19:30 - 24:00 24:00 - 08:00 Ave.Inventory in Bins = Hrs 3 8.5 4.5 8 44100 24 Ave of each hr during this interval Total in this interval (0+3600)/2 = 1800 5400 (3600+3600)/2 = 3600 30600 (3600+0)/2 = 1800 8100 0 = 0 0 Total 44100 = 1,837.50 bbls 3600 1200 = 3 Hrs

5.What is the number of trucks waiting at 6 pm? at 6 pm the total quantity on truck is = Q at 4 pm - Produced berries from 4-6 pm - bin capacity = 6400bbls - 2hr(800 bbls/hr) - 3600 bbls = 1200 bbls Average 100 bbls / truck There are 1200/100 = 12 Trucks are waitng.

6. Of all the trucks that arrive what is the number of trucks that do not have to wait at all? What is the number of truck that have to wait? Arrival rate 1200 bbl/hr or 12 Trucks/hr During 8 hours interval, total arrived trucks 96 Trucks Trucks arriving before the bins are full do not have to wait. From Question 2.,The bins are full at 11:00. So any trucks arrives at 8:00 - 11:00 ( 3 hours) does not have to wait Ans that is 3 hrs * 16 trucks.hr = 36 Trucks Do not need to wait And the rest 96 - 48 = 60 Trucks Have to wait 7. What is the total waiting time (in hours) of trucks? Total truck waiting hours = Q of waiting berries Waiting berries = area above bin capacity = 1/2*1*(4800-3600)+(4800-3600)*4+1/2*4*(6400-4800)+1/2*1.5*(6400-3600) = 10700 bbls . Hr Ans Total truck waiting hours is 107 Truck . Hrs 8. Consider on the trucks that have to wait. How long does such a truck have to wait on the average? From Problem No. 6 -7 60 trucks have to wait and total of waiting time for all waiting trucks is 107 truck. Hr Ans Therefore, Each waiting truck waits for 1.8 hours or 1 hour 48 mins 9. What is the maximum number of trucks waiting at any point in time? The number of trucks will be maximum at 16:00. At this time quantity of berries on the truck is = Total Berries at 16:00 - Bin capacity = 6400-3600 = 2800 bbls Ans Therefore , Maxinum No. of trucks is 28.0 trucks 10. What is the maximum amount of time any truck has to wait? The trucks that have to wait longest is the last truck that arrives. Ans From question No.3, the last truck will have to wait 3.5 hours. 11. Consider a truck that arrives between 2 pm and 3 pm. How long does such a truck have to wait on average? Given : Bin Capacity is 4800bbls Average Berries Quantity that store on the truck between 2- 3 pm is the area under curve between 2 - 3 pm which is above bin capacity of 4800 bbls At 14:00 the Q on truck is Q at 12:00 + 2hr*400bbl/hr - bin capacity = 4800+2*(400)- 4800 = 800 bbls therefore, Truck will have to wait 1 hr At 15:00 the Q on truck is Q at 12:00 + 3hr*400bbl/hr - bin capacity = 4800+3*(400)- 4800 = 1200 bbls therefore, Truck will have to wait 1.5 hr Ans Average truck waiting time between 2 pm to 3 pm is 1.25 hrs

12.What is the maximum time any truck has to wait? Given : Bin Capacity is 4800bbls Ans The trucks that have to wait longest is the last truck that arrives. The Maximum quantity - Bin capacity Plant capacity 800 bbl/hr The maximum time that truck has to wait is 2 6400 bbls 4800 bbls hrs = 2 hrs

When Holding bins capacity is 4,800 bbls and after 16:00 Plant capacity is 400 bbls/hr

Buildup Inventory
7000 6000 5000 4000 3000
2000 1000 4800

6400
4800

3200 1600 0 8:00 0 8:00

12:00

16:00

20:00

24:00

04:00

13. What is the average waiting time (in hours) of trucks? Total Berry quantity waiting is the quantity above 4800 bbls = 1/2 * (20-12) * (6400-4800) = 6400 bbls.hr Or 64.00 Truck .hr Trucks arrives 1200 bbls/hr or 12 Truck/hr During 12:00 - 16:00 ( the interval that the Q is above bin capacity), 4 hours there are 48 Trucks The average waiting time is total truck waiting time/ total truck waiting is 1.33 hrs or 1.00 hrs

Ans

20

mins

14. What is the maximum time any trucks has to wait? Ans The trucks that have to wait longest is the last truck that arrives. The Maximum quantity - Bin capacity Plant capacity 400 bbl/hr The maximum time that truck has to wait is 4 6400 bbls 4800 bbls hrs = 4 hrs

Due on August 1,11

to a berry arrival rate is 1,200 art queueing up as soon as the t 12 noon at the rate of 800 bove repeats itself every day.

ng at 8 am and ending at 8 am

24:00 will be Overtime

t berries arrive at the rate of

oes down to 3600 bbls.

r of truck that have to wait?

ve to wait

e?

pm which is above bin

Time 8:00 12:00 16:00 20:00 24:00 8:00

bbls 0 4800 6400 3200 0 0

Buildup Inventory
7000 6000 5000 4800 6400

Time 8:00 12:00 16:00 20:00 24:00 04:00 8:00

bbls 0 4800 6400 4800 3200 1600 0

4800

4000 3000 2000 1000 0 0 8:00

12:00

16:00

20:00

Time 8:00 12:00 16:00 20:00 24:00 04:00 8:00

bbls 0 4800 6400 4800 3200 1600 0

Time 8:00 12:00 16:00 20:00 24:00 04:00 8:00

bbls 0 4800 6400 4800 3200 1600 0

dup Inventory

4800

3200

1600

20:00

24:00

04:00

0 8:00

3600 7600 8000 10000 6000 0

1800 3800 4000 5000 3000 0

3 1 1 4 10 5

5400 3800 4000 20000 30000 0 63200 2633.333 100 50 50 15 15 15

1 2 3 4 5 6 7

0.5 0.5 1 1 1 0.5 0.5 0.5

1 1 1 1 7.33 4 3.33 2.667

1200 400 1200 1600 1600 2000 2000 1600

600 200 1200 1600 11728 4000 3330 2133.6 24791.6

6.666667 3.333333 3.333333

7 4 4

16.8157 2.6378 -14.1779

3.2612 0.6494 -2.6118

3.2612 0.6494 -2.6118

23.3381

0.8877 0.3467 0.1404 -0.2063

0.1842 0.1842 0.1842 0

0.1842 0.1842 0.1842 0

0.5088