Weldon Hand Tools Case Study

Weldon Hand Tools Case StudyThis report discusses designing a takings process to produce Weldon give-up the ghost tool, the incr console detail, the clock measure for assembling s perpetuallyally fraction as head as the gross sales focus of the crossroad ar all prone in the case study. The report initial start with calculating the subprogram of staff essential for each batch of earn per quarterly for the ii yrs period of the sales apprehend ,then looks at the take technology and facility to assemble the product, it then barely discuss proposed design layout for assembling exertion, diely the report discusses the likely modification of the propose layout should the gather ups step-ups and lastly the report ends with conclusion recommending the need to balance amid enquires and capacity in a well organised production that provide the market with a reliable, and fairly price tool.StaffingIn terms of find out how many staff is call for to transaction in assembling of smoothing flat solid manufacturing plant, given the sales presage for the next two socio-economic phases we read that each employerto works 35 hrs per week for 48 weeks a year excluding the holidays.For simplicity this report leave behind only show the calculation of the inaugural quarter, the 2nd and the last quarter of the 2nd year of sales foreshadow of the staff required and the rest is provide as shown in the circuit board in fig 1 below.2.1- Calculation 1st QuarterThe required consequence of staff for the sales volume in the next two years.We prototypical suppose the total clock time available per quarterly.The sales forecast for the crook one quarter is 98,000 units and given that it takes 1.60 proceeding to assemble one unit, the time needed to assemble the 98,000 units will be98,000 X 1.60= 156800 minutes.In expect the full time workers work 35 mins a week (7 hour a day for 5 work(a) days) one worker working 12 weeks will be35 hrs X 12weeks X 60 minutes=25200 mins consequently number of worker that is needed for manufacturing 98,000 units will be156800/25200= 6.222This will be equivalent to 7 quite a little as at that place is no fraction of people2.2- Calculation 2nd QuarterThe sales forecast for this quarter is 140,000 units, therefore the time requires to assemble it is140,000 X 1.6 = 224000From comparability 1 the time available for one worker will be35 hrs X 12weeks X 60 minutes= 25200 minsHence the number of staff required will be224000/25200 = 8.888 equivalent to 9 peopleSubsequently every quarter is calculated the same till the last quarter. Therefore the sales forecast for the last quarter of the 2nd year is 230,000 units and given that it takes 1.60 minutes to assemble one unit the time needed to assemble will be230,000 units will be 230,000 X 1.60= 368,000 minutes.Therefore the number of people required to work for the quarter will be. Since it was take for granted that full time workers working 35 hour s a week (7 hour a day for 5 working days) one worker working for 12 weeks will be35 hrs X 12weeks X 60 minutes=25200 minsTherefore number of worker that is needed for manufacturing 98,000 unitwill be 368,000/25200= 14.603This will be equivalent to 15 people as there is no fraction of people.In conclusion we see the demand is not constant and there is inflation and deflation in demand to go this we either employ more worker or ask the lively staff to do some extra over time when ever demand increaseFacilities and technologySince the sales forecast shows a eminent demand selecting the required facilities and technology in designing the manufacturing process for Weldon slew tools is very crucial therefore the first and foremost things to consider is the coat of the facility and if there is room for expansion .the operation process and the required work forceWe need to have in place working capital and aim, proper provision of the process, research on customer requirement, semin ars and training to vie in the market as the sales forecast shows increase and fall down in demand and finally managing the inventory by having warehouse for the stocks make smoothing plane can be divided into three major area, navigate calf loveing, bench operation and peignoir, other than fly pressing which requires pressingmachine,the general operation is reasonably simple so some of the technology and facilities required arePress machines for press operationCustomised kits for efficient bench operationStapler, truck, and wrapping bench for easy handling of tools and wrappingDesign layoutDesign layout is crucial process in operation management ,the flow of the layout very much relies on the volume and variety characteristic which shapes the overall design (Slack et al, 2010).The determination as to which layout type to adopt will be influenced by an pinch of their relative advantages and disadvantages (Slack et al, 2010).Therefore in order to design the layout we need first to identify the type of manufacturing process that smoothing planes is. As per the case study and fit to its sales focus there is indication that this is high volume create and low variety operation and so this can be class as a mass process manufacturing process and so product base layout is the appropriate design layout.Since that the new product has a akin design with little variation, the design layout can be the same as the small variation does not affect the fundamental production process. in conclusion the main factors that determine the design layout in this case study is the ease in which expansion can be made to meet the increase demand, focusing on the process to combine flexibility with a lower limit lead timeare the main The layout therefore can be organised in simple and flexible manner so as to enhance the travel rapidly of production and reduce inventory while meeting the expected increase of demandThe first task is solely a fly press operation in order to minimise idle time among the work stations. The operation will be organised such as each unit recovers the goods from the previous unit4.1- Layout submitsS0 by numbering the subdivision available to assemble the task 1-12 so as to calculate the number of e stages required for the product layout.This is worked out by requiring the bout time, sluice though the cycle time for each quarter was shown in the supra table in Fiq1, we will show the calculation of how it was arrive , just in term of calculating the stages we only need the sales of the first quarterSince the sales forecast for the first quarter is 98,000 unit and given that it takes 1.60 minutes to assemble one unit, its assume that full time workers work 35 hours a week (7 hour a day for 5 working days)the net time available for work in 12 weeks(1st quarter) will be35 hrs. X 12weeks X 60 minutes=25200 minutesTherefore the required cycle time =total time available/work volume25200/98000= 0.257 minsNo of stages required w ill be = total volume /cycle time1.6/0.257 = 6.222= 7 stagesHaving known the number of stages we then list the element 1-2 and draw the precedence diagram to calculate the balancing loss particle 1 Assemble poke subassembly 0.12 share 2 Fit poke subassembly to frog 0.10 atom 3 centre adjusting level to frog 0.15 component part 4 Press adjusting nut cheat on to frog 0.08Element 5 Fit adjusting nut to frog 0.15Element 6 Fit frog screw to frog 0.05Element 7 Fit knob to base 0.15Element 8 Fit shroud to base 0.17Element 9 Fit frog subassembly to base 0.15Element 10 Assemble brand subassembly 0.08Element 11 Assemble blade subassembly,clamp and label to base and adjust 0.20Element 12 touch on up box and wrap plane,pack and stock 0.20Fiq3below displays the final dissemination of work after breaking down the process into different stages of the pine thin arrangement, the advantage is that its an ideal way of arranging flexible and expandible operation., makes moving and handling ver idicals between unit effective and as well as providing adequate amount of floor space .0.15 0.08 0. 12 0.10 0.08 0.15 0.05 0.15 0.17 0.15 0.20 0.20Fig2 Element listing and precedence diagram4.2- Calculating balancing loss0.15 0.08 0. 12 0.10 0.08 0.15 0.05 0.15 0.17 0.15 0.20 0.20Stage1 stage2 satge3 stage4 satge5 stage6 stage7 stage8Cycle time = 0.260.230.230.220.200.200.200.170.151 2 3 4 5 6 7 8Idle time of every cycle =(0.26-0.22)+(0.26-0.25)+(0.26-0.20)+(0.26-0.15)+(0.26-0.17)+(0.26-0.23)+(0.26-0.20)+0.26-0.20) = 0.45Balance loss = 0.45/8 0.26 = 21.6 %Fig 3 Allocation of element to stages and balancing loss for Weldon hand toolfig2Meeting the demandIn meeting increasing demand the above design layout can be adjusted by rearranging the stages. The conventional arrangement of the eight stages was to arrange them in one line and each stage takes 0.257 minutes (cycle time) worth of work however this can be rearranged in to four shorter lines each stage with 0.514 minutes worth of work will give the same output. So following this conclusion the stages could be arranged in 8 line of latitude stages each responsible for the whole worked content, the advantage is that it will save time for product transportation both within the site and the nearby twist where facilities are located, create plenty of space within the site therefrom enhancing easy expansion to meet increase in demand and finally the inventory will too assist to place the product well in stockLastly the above layout has concentrated on the labour time effectiveness of assembling one unit per hour per person,however concentrating on speed and quickness of machines may understand any competition of demand and capacityConclusionIn operational management capacity planning such knowing what is the size of the facilities, the geographical location and the row material for the production process is fundamental, crucial and necessaryTo successful manage the Weldon hand tool manufactu ring process its desirable that the layout be design in a flexible way to rearrange stages that will create more live for expansion so as to meet future demands and capacity. The flexibility also makes the transportation (moving and handling) of materials between unit effectiveFinally at the instant the sales forecast does not predicts smooth distribution of demand to encounter this problem of inflation and deflation of the sales, marketing the product through sales procession could improve the demand distribution to a smooth increase end-to-end the quarters.