Kinga Doll Company manufactures eight versions of its popular girl doll, Shari. The company operates on a 40-hour workweek. The eight versions differ in doll skin, hair, and eye color, enabling most children to have a doll with a similar appearance to them. It currently sells an average of 4,500 dolls (spread equally among its eight versions) per week to boutique toy retailers. In simplified terms, doll making at Kinga involves three basic operations: molding the body and hair, painting the face, and dressing the doll. Changing over between versions requires setup time at the molding and painting stations due to the different colors of plastic pellets, hair, and eye color paint required. The following table lists the setup and processing times for a batch and the activity times for each unit at each step.
Process Step Molding Painting Dressing
Setup time (minute) 14.00 33.00 No setup
Processing time (minute) 0.26 0.12 0.31
What is the process capacity in dolls per hour with a batch size of 450 dolls?
Note: Do not round intermediate calculations. Round your final answer to nearest whole number.
What is the utilization of molding in dolls per hour with a batch size of 725 dolls?
Note: Do not round intermediate calculations. Round your answer to 2 decimal places.
Which batch size would minimize inventory without decreasing the process capacity?
Note: Do not round intermediate calculations. Round your final answer to nearest whole number.
Which batch size would minimize inventory without decreasing the current flow rate?
Note: Do not round intermediate calculations. Round your final answer to nearest whole number.