a) hourly production rate of the plant, (b) number of workers and workstations required
A final assembly plant for a certain automobile
model is to have a capacity of 240,000 units annually.
The plant will operate 50 wk/yr, 2 shifts/day, 5 days/
wk, and 8.0 hr/shift. It will be divided into three departments: (1) body shop, (2) paint shop, (3) trim-chassis-final department. The body shop welds the car bodies using robots, and the paint shop coats the bodies. Both of these departments are highly auto-
mated. Trim-chassis-final has no automation. There are 15.5 hr of direct labor content on each car in this department, where cars are moved by a continuous conveyor. Determine (a) hourly production rate of
the plant, (b) number of workers and workstations required in trim-chassis-final if no automated stations are used, the average manning level is 2.5, balancing efficiency 1⁄4 93%, proportion uptime 1⁄4
95%, and a repositioning time of 0.15 min is allowed
for each worker.
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