Question 2

'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 1st

quarter of production:

a) The required cycle time and the theoretical minimum number of people required to

assemble the products

b) The 'line design'.

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?

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?

e) Considering the two options. Which layout is best suited to meet the demand in 4th

quarter and why?

f) What are the advantages and disadvantages of both 'long thin' and 'short fat'

layouts?