Scribd Logo
Upload

Welcome to Scribd!

  • 747 views

    Power Toys

    Uploaded by

    Sashi Velnati
    The document describes a process to assemble toy trucks on a conveyor belt production line with 9 stations. Each station currently has one worker and tasks take between 55-90 seconds. The bottleneck is station 3 which takes 90 seconds to insert a chip. The current production capacity is 40 toy trucks per hour. With 9 workers paid $15/hour, the direct labor cost per truck is $3.38. If tasks were consolidated to one worker, capacity would be 5.4 trucks per hour and cost $2.77 per truck. Due to reduced demand, staffing will be cut to 6 workers who must be assigned adjacent tasks. The new production capacity is 24.8 toy trucks per hour.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd

    Power Toys

    Uploaded by

    Sashi Velnati
    747 views3 pages
    The document describes a process to assemble toy trucks on a conveyor belt production line with 9 stations. Each station currently has one worker and tasks take between 55-90 seconds. The bottleneck is station 3 which takes 90 seconds to insert a chip. The current production capacity is 40 toy trucks per hour. With 9 workers paid $15/hour, the direct labor cost per truck is $3.38. If tasks were consolidated to one worker, capacity would be 5.4 trucks per hour and cost $2.77 per truck. Due to reduced demand, staffing will be cut to 6 workers who must be assigned adjacent tasks. The new production capacity is 24.8 toy trucks per hour.

    Original Description:

    Supply chain problem solution

    Copyright

    © © All Rights Reserved

    Available Formats

    DOCX, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document describes a process to assemble toy trucks on a conveyor belt production line with 9 stations. Each station currently has one worker and tasks take between 55-90 seconds. The bottleneck is station 3 which takes 90 seconds to insert a chip. The current production capacity is 40 toy trucks per hour. With 9 workers paid $15/hour, the direct labor cost per truck is $3.38. If tasks were consolidated to one worker, capacity would be 5.4 trucks per hour and cost $2.77 per truck. Due to reduced demand, staffing will be cut to 6 workers who must be assigned adjacent tasks. The new production capacity is 24.8 toy trucks per hour.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    747 views3 pages

    Power Toys

    Uploaded by

    Sashi Velnati
    The document describes a process to assemble toy trucks on a conveyor belt production line with 9 stations. Each station currently has one worker and tasks take between 55-90 seconds. The bottleneck is station 3 which takes 90 seconds to insert a chip. The current production capacity is 40 toy trucks per hour. With 9 workers paid $15/hour, the direct labor cost per truck is $3.38. If tasks were consolidated to one worker, capacity would be 5.4 trucks per hour and cost $2.77 per truck. Due to reduced demand, staffing will be cut to 6 workers who must be assigned adjacent tasks. The new production capacity is 24.8 toy trucks per hour.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    of 3

    Q 4.

    3 POWERTOYS
    PowerToys Inc produces a small remote-controlled toy truck on a conveyor belt with
    nine stations. Each station has, under the current process layout, on worker
    assigned to it. Stations and processing times are summarized in the following table:

    Station Task Processing Times (seconds)


    1. Mount battery units 75
    2. Insert remote control receiver 85
    3. Insert chip 90
    4. mount front axle 65
    5. mount back axle 70
    6. install electric mirror 55
    7. connect motor to battery unit 80
    8. connect motor to rear axle 65
    9. mount plastic body 80

    a. What is the bottleneck in this process?


    The bottleneck in the process is the step with the maximum time out of all
    the 9 steps, Step 3 Insert Chip (90 Seconds)
    b. What is the capacity, in toy trucks per hour, of the assembly line
    Step
    1

    Activity
    Mount battery units

    Insert remote control


    receiver
    Insert chip

    mount front axle

    Se
    c
    75
    85
    90
    65

    Hrs
    0.0208
    33
    0.0236
    11
    0.025
    0.0180
    56

    Capac
    ity
    48.0
    42.4
    40.0
    55.4

    mount back axle

    70

    install electric mirror

    55

    7
    8
    9

    connect motor to battery


    unit
    connect motor to rear
    axle
    mount plastic body

    80
    65
    80

    0.0194
    44
    0.0152
    78
    0.0222
    22
    0.0180
    56
    0.0222
    22

    51.4
    65.5
    45.0
    55.4
    45.0

    Flowrate = Minimum (48.0, 42.4, 40.0, 55.4, 51.4, 65.5, 45.0, 55.4, 45) = 40
    Units/hr
    c. What is the direct labor cost for the toy truck with the current process if each
    worker receives $15/hour, expressed in dollars per toy truck?
    Total hourly Labor cost for 9 workers = 9*$15 = $135
    Labor cost per hour/Flowrate = $135/40 units/hr = $3.38 $ per unit
    d. What would be the direct labor cost for the toy truck if work would be organized
    in a work cell, that is, one worker performs all tasks? Assume that the processing
    times would remain unchanged (ie, there are no specialization gains).
    Labor Content = Sum (75, 85, 90, 65, 70, 55, 80, 65, 80) = 665 seconds per
    unit
    Number of units in an hour = 3600/665 = 5.4135 units an hour
    @ $15 an hour the Labor cost = $15*1(# of workers)/5.4135 units = 2.77$
    per unit
    e. What is the utilization of the worker in station 2?
    Flow rate for the whole line is 40 units per hour from (b)
    Capacity at Station 2 from the table above is 42.4 units per hour
    Utilitzation of the worker = 40/42.4 * 100 = 94.3396%

    Because of a drastically reduced forecast, the plant management has decided to cut
    staffing from nine to six workers per shift. Assume that (i) the nine tasks in the
    preceding table cannot be divided; (ii) the nine tasks are assigned to the six workers

    in the most efficient way possible; and (iii) if one worker is in charge of two tasks,
    the tasks have to be adjacent (i.e., one worker cannot work on tasks 1 and 3).

    f. How would you assign the nine tasks to the six workers?
    Workers are allocated based on the lowest adjacent activity time to balance
    the workload
    Work
    er

    Step

    3
    4

    4
    5
    6
    5
    7
    8
    6
    9

    Activity
    Mount battery
    units
    Insert remote
    control receiver
    Insert chip
    mount front
    axle
    mount back
    axle
    install electric
    mirror
    connect motor
    to battery unit
    connect motor
    to rear axle
    mount plastic
    body

    Sec

    Statio
    n
    Time

    75

    75

    85

    85

    90

    90

    0.0208
    33
    0.0236
    11
    0.025

    135

    0.0375

    26.7

    135

    0.0375

    26.7

    145

    0.0402
    78

    24.8

    Hrs

    Unit
    s
    48.0
    42.4
    40.0

    65
    70
    55
    80
    65
    80

    g. What is the new capacity of the line (in toy trucks per hour)?
    Flowrate = Minimum (48.0, 42.4, 40.0, 26.7, 26.7, 24.8) = 24.8 Units/hr

    You might also like