THIS SOLUTION MAY ONLY BE USED FOR IE 1055/2025 SPRING 2017. IE 1055/2025 Homework 9 Due March 29, 2017 1. (18 pts) Critique of sample project one. 2. (18 pts) Critique of sample project two. 3. (18 pts) Analyze the following vaccine capacity problem. The packaged volume of single dose vaccines is given in the table below. At a given location, you need to have 11000 doses of each vaccine type. The location you are analyzing uses refrigerators with storage compartment dimensions of 24 inches by 20 inches by 18 inches. Assuming all vaccines are only stored in the refrigerator, how many refrigerators do you need? Fully justify your answer. Vaccine Name Packaged volume in cm3 DTP 3 DTP-HepB-Hib 9.7 Measles 3.5 Oral Polio 1 Tetanus Toxoid 3 Tuberculosis 1.2 Yellow Fever 2.5 Solution (18 pts): Calculate the storage space inside the refrigerator (1 in = 2.54 cm) (24*2.54) * (20*2.54) * (18*2.54) = 141584.2 cm3 Sum the packaged volumes, and you obtain 23.9 mL (1 cm3 = 1 mL) then multiply the total number of doses needed by the total packaged amounts. (3+9.7+3.5+1+3+1.2+2.5) * 11000= 262900 cm3 Assuming we get 100% utilization of the refrigerators, the volume per refrigerator is 141.6L or 141584.2 mL. If we divide our total volume of packaged vaccines by the volume per refrigerator we get 262900/141584.2 = 1.86 Refrigerators needed. If we assume that we can only get 90% utilization of the volume in the refrigerator, the adjusted volume is .9*141584.2= 127425.8 mL. Using the same methodology as above, if we divide 262900/ 127425.8= 2.06 Refrigerators needed. In reality, you are probably doing well to get 75% utilization of the refrigerator. For 75% the adjusted volume is .75*141584.2= 106188.2 mL. Using the same methodology as above, if we divide 262900/ 106188.2= 2.48 Refrigerators needed. Thus, overall it seems that 3 Refrigerators are needed.THIS SOLUTION MAY ONLY BE USED FOR IE 1055/2025 SPRING 2017. 4. (13 pts) At the MSA site in Cranberry they have chosen to receive all of their cardboard boxes used for test devices from their suppliers already constructed as opposed to receiving flat cardboard sheets (sized and perforated as needed) and constructing the boxes themselves. These boxes are on average 4-8 inches long, 2-4 inches high and 3-6 inches wide. Discuss some of the pros and cons of using this strategy concerning cardboard boxes. Solution (13 pts): Pros: - Reduce assembly time because the boxes will not need to be set up - Reduce assembly cost because less labor is required per test device - Increase capacity of assemblers because of less time setting up boxes - Reduce cost of materials to assemble boxes (tape, scissors, etc.) Cons: - Boxes will be more expensive when pre-assembled - Storing assembled boxes takes up significantly more space than storing collapsed boxes - Shipping costs will increase because of more space required to transport boxes (i.e. less boxes per shipment) - Boxes are more likely to be damaged if stored/transported when assembled as opposed to collapsed 5. (18 pts) MedTech is a manufacturer of disposable syringes used in the medical industry. After the disposable syringes are manufactured and packaged there is an FDA requirement that the syringes be sterilized before they can be shipped from MedTech’s facility. The sterilization occurs in a large chamber and currently has a 12 hour cycle time (including the time to load and unload the chamber). MedTech currently has 3 sterilization chambers that have an average uptime of 98%. The diagram below shows how pallets of syringes are loaded into the sterilization chamber. The pallets are 48 inches by 54 inches and it takes about 10 minutes to load (unload) the pallets into (out of) the chamber. The outer dimensions of the chamber are 14 feet by 28 feet and the usable area of the chamber that can hold pallets is 10 feet wide and 21.5 feet long. MedTech currently runs the sterilization operation 24 hours a day, 7 days a week. 54′′ 48′′ 21.5′10′THIS SOLUTION MAY ONLY BE USED FOR IE 1055/2025 SPRING 2017. MedTech’s current production schedule requires them to sterilize 300 pallets per week. In the next year MedTech sees that increasing to 340-350 per week, in two years to 350-375 per week, and in three years to 380-400 per week. In order to obtain increased sterilization capacity MedTech is considering the following options: i. Change the sterilization gas that they use in order to reduce the cycle time to 9 hours. Changes to the equipment due to the gas conversion would cost $362,000 over the next 2 years. Annual sterilization gas costs for the new gas would be roughly equal to the gas costs for the current sterilization gas. ii. Purchase an additional sterilizer of the type they currently have at a cost of $417,000. iii. Outsource additional sterilization, but the cost of outsourcing is 36% higher per disposable syringe than the cost of sterilizing in-house. Which option and/or other ideas would you recommend to MedTech? Answer (18 Pts): Current dimensions of the 3 chambers are 10’x21.5’ which translates to 120”x258”. The current pallet configuration allows for: floor(120/48)*floor(258/54)=8 pallets/chamber The current situation allows for: (8 pallets/chamber)*(24 hrs/day)/(12 hrs for cycle)*(0.98 utilization)*(3 chambers)=47.04 pallets/day At the end of a 7 day week, MedTech can produce 7*45.6=329.28 or 329 pallets/week. This production rate is sufficient for current demand. But will not be able to keep up with demand in future years. Option 1: Reduce cycle time to 9 hours (8 pallets/chamber)*(24 hrs/day)/(9 hrs for cycle)*(0.98 utilization)*(3 chambers)=62.72 pallets/day At the end of the week, MedTech can produce 7*62.72=439.04 or 439 pallets/week. This production rate is sufficient for predicted demand in three years. The cost of this option is $362,000 over 2 years. No other cost data was provided. Option 2: Purchase a new sterilization chamber (8 pallets/chamber)*(24 hrs/day)/(12 hrs for cycle)*(0.98 utilization)*(4 chambers)=62.72 pallets/day At the end of the week, MedTech can produce 7*62.72=439.04 or 439 pallets/week. This production rate is sufficient for predicted demand in three years. The cost of this option is $417,000. No cost data, such as the cost of labor needed to run the new machine, was provided. Option 3: Outsource Current production is 329 pallets/week with expected demand of 400 pallets/week in