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Al Beck, president of Beck Manufacturing, has decided to implement the Theory of Constraints 5-step thinking process in his manufacturing facility, which produces steering gears for auto manufacturers. The operation produces large numbers of nearly identical products. The image above shows the manufacturing process for gears. As shown in the diagram, there are two possible processes in production. 50% of steering gears go through process A, and 50% of steering gears go through process B.
Total customer demand is 200 steering gears per hour. Al is able to buy all the parts he needs for production. The factory operates 8 hours per day. He has found that Sub-Assembly Dept. A can produce 110 sub-assemblies per hour, Sub-Assembly Dept. B can produce 120 sub-assemblies per hour, Final Assembly Dept. can produce 200 products per hour, and Testing Dept. can test 210 steering gears per hour.
Apply Step 1 of the TOC 5-step thinking process. In the current process, the bottleneck is Hint, displayed below-Select-.
A For Beck Manufacturing, the effective capacity of the system is Hint, displayed below-Select-.
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