No of Operations Required for Each Part 12 40 25 30 No of Category Models No of

Question

No of Operations Required for Each Part 12 40 25 30 No of Category Models No of Parts in Each Model 2 15 QTY of Each Model 1000 200 4 4 10 100 2500 28 Based on time measurements done, on average, each operation takes 45 Sec. The factory lay out is comprised of workstations which have one set of machinery and one operator. Each station required 200 sq-ft of spaces as well as 100 sq-ft of auxiliary space The factory is running one 8-hour shift per day for 250 days per year 1. 2. 3. 4. 5. 6. What is the total number of styles/models Alpha manufacturing? What is the total number of products Alpha manufacturing? What is the number of required operators? What is the number of required stations? How much is the required space for the facility? If the company decides to run 3 eight-hour shifts per day, then; How many stations are required How much space is required a. b. 7. Comparing No of required stations and space for both cases, what do you infer? Note: Please distinctly, provide all the required steps

Explanation / Answer

(1)

No. of styles = 4+3+5+10+2 = 24

(2)

(3)

Each operation takes 45 sec.

So, total time required = 2441000 x 45 = 109845000 sec

One worker has time per year = 250 days x 8 hours per day x 3600 sec per hour = 7200000 sec

So, No. of operators required = 109845000 / 7200000 = 15.26 (or 16)

(4)

Since one station contains one operator,

No. of stations = 16

(5)

Required space = 16 x (200 sqft. + 100 sqft.) = 4800 sqft

(6)

For 3 shifts operations, clearly the production requirement will be distributed to 3 shifts and the number of operators required in each shift will be = 15.26 / 3 = 5.09 (or, 6)

No. of stations required = 6 ---------(a)

Space required = 6 x (200 sqft. + 100 sqft.) = 1800 sqft --------(b)

(7)

Category No of Models
(A) QTY of Each Model
(B) Total no. of products
(A x B) 1 4 1000 4000 2 3 200 600 3 5 500 2500 4 10 100 1000 5 2 2500 5000 Total 13100

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