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(5 Marks) (5 Marks)

Smoothtools wants to manufacture a wood plane to enter the woodworking tools market. It has developed a build sequence and timing for each assembly task, and the marketing department has produced a sales forecast. The question asks to determine the cycle time, minimum number of people needed, line design, actual number of people, balance loss and estimated output for a long thin layout in the 1st quarter of production. It also asks to compare this to using a short fat layout in the 4th quarter.

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Haseeb Javed
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76 views3 pages

(5 Marks) (5 Marks)

Smoothtools wants to manufacture a wood plane to enter the woodworking tools market. It has developed a build sequence and timing for each assembly task, and the marketing department has produced a sales forecast. The question asks to determine the cycle time, minimum number of people needed, line design, actual number of people, balance loss and estimated output for a long thin layout in the 1st quarter of production. It also asks to compare this to using a short fat layout in the 4th quarter.

Uploaded by

Haseeb Javed
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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‘Smoothtools’ manufacturing company want to enter the ‘woodworking tools’ market and

one of the first products it has decided to manufacture is a general purpose smoothing
plane. (See Figure Q2- parts view). After ‘reverse engineering’ the wood plane, the
planning department have arrived at a build sequence and timings for each task which is
shown in Table Q2(a). Furthermore, the marketing department at ‘Smoothtools’ have
produced a sales forecast for the new planes which is given in Table Q2(b). The plant is
expected to have a work pattern of 40 hours week, 48 weeks per year. Assuming a
Product layout (Long thin) arrangement, determine the following information for the 1 st
quarter of production:

a) The required cycle time and the theoretical minimum number of people required to
assemble the products
(5 Marks)
b) The ‘line design’.
(5 Marks)

c) The actual number of people required to manufacture/assemble the product based


on your design and what would be the balance loss and estimated output for this
arrangement?
(6 Marks)

d) If a ‘short fat’ layout is used in the 1st quarter, how many people would be required
to assemble the products? What is the balance loss and potential output for this
arrangement?
(6 Marks)

e) Considering the two options. Which layout is best suited to meet the demand in 4 th
quarter and why?
(12 Marks)

f) What are the advantages and disadvantages of both ‘long thin’ and ‘short fat’
layouts?
(16 Marks)

Figure Q2 Exploded view of wood plane


TAS ELEMENT TIME (Seconds)
K

PRESS OPERATIONS

A Build poke sub-assembly 7 secs

B Fit poke assembly to frog 6 secs

C Rivet adjusting lever to frog 9 secs

D Press adjusting nut screw to frog 5 secs

BENCH OPERATIONS

E Fit adjusting nut to frog 9 secs

F Fit frog screw to frog 3 secs

G Fit knob to base 9 secs

H Fit handle to base 10 secs

I Fit frog sub-assembly to base 9 secs

J Assemble blade sub-assembly 5 secs

K Assemble blade sub-assembly , clamp and label to base and 12 secs


adjust/inspect

L Make up box and wrap plane, pack and stock 12 secs

Table Q2(a) Standard time for each task and build sequence

Period

Year 1 Units

1st quarter 112000

2nd quarter 140000

3rd quarter 140000

4th quarter 230000

Table Q2(b) Sales forecast Year 1

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