Problem NO: 4

A final assembly plant for a certain automobile model is to have a capacity of 240,000 units\nannually. The plant will operate 50 weeks/yr, 2 shifts/da

A final assembly plant for a certain automobile model is to have a capacity of 240,000 units

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annually. The plant will operate 50 weeks/yr, 2 shifts/day, 5 days/week, and 8.0 hours/shift. It will

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be divided into three departments: (1) body shop, (2) paint shop, (3) trim-chassis-final department.

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The body shop welds the car bodies using robots, and the paint shop coats the bodies. Both of these

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departments are highly automated. Trim-chassis-final has no automation. There are 15.5 hours of

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direct labor content on each car in this department, where cars are moved by a continuous conveyor.

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Determine (a) hourly production rate of the plant, (b) number of workers and workstations required

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in trim-chassis-final if no automated stations are used, the average manning level is 2.5, balancing

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efficiency = 93%, proportion uptime = 95%, and a repositioning time of 0.15 min is allowed for

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each worker.

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