new gom3-supplement and exercise

GOM3ExerciseReturntoKingforUsingMoreMachinesNumberofMachinesTypeofnextmachineMachineTimes(min)CycleTime(min)TotalHourlyOutputEfficiency(%)ABCD4--4310210647.55C435251276.067891011121314ReturntoKingforUsingMoreMachinesNumberofMachinesTypeofnextmachineMachineTimes(min)CycleTime(min)TotalHourlyOutputEfficiency(%)ABCD4--4310210647.55C435251276.06C433.33241579.27A233.3323.331881.48C232.5232079.29B21.52.522.52484.410C21.52223095.011D21.52123086.012A1.331.52123079.213C1.331.51.6711.673687.514C1.331.51.4311.54090.5Question:ThemodelJWagonistobeassembledonaconveyorbelt.Fivehundredwagonsarerequiredperday.Productiontimeperdayis420minutes,andtheassemblystepsandtimesforthewagonaregiveninthefollowingExhibit.Assignment:findthebalancethatminimizesthenumberofworkstations,subjecttocycletimeandprecedenceconstraints.TASKTASKTIMEINSECONDSDESCRIPTIONTASKSTHATMUSTPRECEDEA45Positionrearaxlesupportandhandfastenfourscrewstonuts.--B11InsertrearaxleAC9TightenrearaxlesupportscrewstonutsBD50Positionfrontaxleassemblyandhandfastenwithfourscrewstonuts--E15TightenfrontaxleassemblyscrewsDF12Positionrearwheel#1andfastenhubcap.CG12Positionrearwheel#2andfastenhubcap.CH12Positionfrontwheel#1andfastenhubcap.EI12Positionfrontwheel#2andfastenhubcap.EJ8PositionwagonhandleshaftonfrontaxleassemblyandhandfastenboltandnutF,G,H,IK9TightenboltandnutJ1951.DrawaPrecedenceDiagram.ABCFJDEHIGK45sec50sec11sec15sec9sec12sec12sec12sec12sec8sec9sec4.5050025200500min420sec60wagondayperoutputdaypertimeproductionC)(487.3sec4.50sec195uproundedondsondsCTNt2.Determineworkstationcycletime.HerewehavetoconverttosecondsbecauseOurtasktimeareinseconds3.Determinethetheoreticalminimumnumberofworkstationsrequired(theActualnumbermaybegreater.ABCFJDEHIGK45sec50sec11sec15sec9sec12sec12sec12sec12sec8sec9secWS1WS2WS3:B,E,C,FWS4:G,H,I,JWS5%7777.)4.50)(5(195orNTEfficiencyTASKNUMBEROFFOLLOINGTASKSA6BorD5CorE4F,G,HorI2J1K04.Selectassignmentrulesa.assigntasksinorderofthelargestnumberoffollowingtasksb.assigntasksinorderoflongesttasktime5.MaketaskassignmentstoformWorkstation1,Workstation2…..6.Calculateefficiency:assume5first?7.Evaluatethesolution.Anefficiencyof77percentindicatesanimbalanceoridletimeof27percentacrosstheentireline.8.Isabetterbalancepossible?Yes,Trybalancingthelinewithruleb.andbreaktieswithrulea.(Thiswillgiveyo0uafeasiblefour-stationbalance.QuestionAcompanyisconsideringaddinganewfeaturethatwillincreaseunitsalesby6percentandproductcostby10percent.Profitisexpectedtoincreaseby16percentoftheincreasedsales.Initiallytheproductcostincurredbythecompanywas63percentofthesalesprice.Shouldbethefeaturebeadded?Letthesalesbe$100M.SolutionDay1Problem1Salesincreaseby6%=$100Mx6%=$6MBenefits:Profitsincreaseby16%oftheincreasedsales=$6Mx16%=$0.96MCost:Increaseproductcostby10%=($100Mx63%)x10%=$6.3MBecausecostsexceedbenefits,thenewfeatureshouldnotbeadded.QuestionAnautomobilemanufacturerisconsideringachangeinanassemblylinethatshouldsavemoneyduetoareductioninlaborandmaterialcost.Thechangeinvolvestheinstallationoffournewrobotsthatwillautomaticallyinstallwindshields.Thecostofthefourrobots,includinginstallationandinitialprogramming,is$400,000.Currentpracticeistoamortizetheinitialcostofrobotsovertwoyearsonastraight-linebasis.Theprocessengineerestimatesthatonefull-timetechnicianwillbeneededtomonitor,maintain,andreprogramtherobotsonanongoingbasis.Thispersonwillcostapproximately$60,000peryear.Currently,thecompanyusesfourfull-timeemployeesonthisjobandtheyeachmakeabout$52,000peryear.Oneoftheseemployeesisamaterialhandler,andthispersonwillstillbeneededwiththenewprocess.Tocomplicatematters,theprocessengineerestimatesthattherobotswillapplythewindshieldsealingmaterialinamannerthatwillresultinasavingsof$0.25perwindshieldinstalled.Howmanyautomobilesneedtobeproducedoverthenexttwoyearstomakethenewrobotsanattractiveinvestment?Duetotherelativelyshorthorizon,donotconsiderthetimevalueofmoney.Solution:Costofthecurrentprocessoverthenexttwoyearsisjustthecostofthefourfull-timeemployees.$52,000/employeesx4employeesx2years=$416,000Thecostofthenewprocessoverthenexttwoyears,assumingtherobotiscompletelycostedoverthattime,isthefollowing:($52,000/materialhandler+$60,000/technician)x2+$400,000/robots-$0.25xautosEquatingthetwoalternatives:$416,000=$624,000-$0.25xautosSolvingforthebreak-evenpoint:-$208,000/-$0.25=832,000autosThisindicatesthattobreakeven,832,000autoswouldneedtobeproducedwiththerobotsoverthenexttwoyears.ISO9000seriesQualitysystem9001:modelforqualityassuranceindesign,production,installation,andservicing9002:modelqualityassuranceinproductionandinstallation.9003:modelforqualityassuranceinfinalinspectiontest.GuidelinesforUse9000:qualitymanagementandqualityassurancestandards—guidelinesforselectionanduse.Qualitymanagementandqualityelements--guidelinesQualitySystemDesign/developmentProcurementProductionInstallationServicingISO9002Design/developmentProcurementProductionInstallationServicingISO9003ISO9001QuestionManagementistryingtodecidewhetherPartA,whichisproducedwithaconsistent3perce