Power Toys Inc produces small remote controlled toy trucks on a conveyor
belt with nine stations. Each station has , under the current process
layout, one worker assigned to it. Stations and processing times are
summarized in the following table:
Station Task Processing Times (seconds)
1 Mount Battery unit 75
2 Insert remote control receiver 85
3 Insert chip 90
4 Mount front axel 65
5 Mount back axel 70
6 Install electric motor 55
7 Connect motor to battery unit 80
8 Connect motor to rear axel 65
9 Mount plastic body 80
What is the bottleneck in this process?
What is the capacity, in toy trucks per hour, of the assembly line
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?
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 activity times would remain unchanged (i.e., there are
no specialization gains).
What is the utilization of the workers in Station 2?
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 above table cannot be divided; (ii) the nine
tasks are assigned to six workers in the most efficient way possible;
and (iii) if one worker in charge of two tasks, the tasks have to be
adjacent (e.g., one worker cannot work on tasks 1 and 3)
How would you assign the nine tasks to six workers?
What is the new capacity of the line (in toy trucks per hour)?
Business Homework Solutions
#41326
Power Toys: bottleneck in processing times, reassign duties, new capacity
See attached file for the table.
Questions:
Power Toys Inc produces small remote controlled toy trucks on a conveyor belt with nine stations. Each station has , under the current process layout, one worker assigned to it. Stations and processing times are summarized in the attached table.
a) What is the bottleneck in this process?
b) What is the capacity, in toy trucks per hour, of the assembly line
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?
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 activity times would remain unchanged (i.e., there are no specialization gains).
e) What is the utilization of the workers in Station 2?
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 above table cannot be divided; (ii) the nine tasks are assigned to six workers in the most efficient way possible; and (iii) if one worker in charge of two tasks, the tasks have to be adjacent (e.g., one worker cannot work on tasks 1 and 3)
f) How would you assign the nine tasks to six workers?
g) What is the new capacity of the line (in toy trucks per hour)?
The solution provides a sentence or two or explanation for each question plus calculations as needed.
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