Weldon Hand Tools Case Study

Weldon Hand Tools Case StudyThis penning discusses designing a achievement impact to father Weldon hand tool, the fruit detail, the time for assembling all(prenominal) gene as well as the gross revenue focus of the product are all precondition in the case study. The report introductory start with calculating the number of staff essential for each volume of take to the woods per makely for the two days period of the gross revenue medical prognosis ,then looks at the have technology and facility to assemble the product, it then further discuss proposed design layout for assembling operation, lastly the report discusses the likely adjustment of the propose layout should the demands annexs and finally the report ends with conclusion recommending the need to balance between demands and capacity in a well organised end product that supply the market with a reliable, and fairly price tool.StaffingIn terms of determining how many staff is needed to tend in assembling of s moothing s commit manufacturing plant, given the sales cypher for the next two years we assume that each employerto engages 35 hours per week for 48 weeks a year excluding the holidays.For straightforwardness this report get out only show the calculation of the 1st quarter, the 2nd and the last quarter of the 2nd year of sales forecast of the staff required and the rest is provide as shown in the table in fig 1 below.2.1- Calculation 1st QuarterThe required number of staff for the sales volume in the next two years.We first calculate the total time available per quarterly.The sales forecast for the first quarter is 98,000 units and given that it takes 1.60 proceedings to assemble one and only(a) unit, the time needed to assemble the 98,000 units pull up stakes be98,000 X 1.60= 156800 mi icees.In assuming the full time workers work 35 hours a week (7 hour a day for 5 working days) one worker working 12 weeks go out be35 hrs X 12weeks X 60 minutes=25200 minsTherefore number of worker that is needed for manufacturing 98,000 units will be156800/25200= 6.222This will be equivalent to 7 people as there is no fraction of people2.2- Calculation 2nd QuarterThe sales forecast for this quarter is 140,000 units, wherefore the time requires to assemble it is140,000 X 1.6 = 224000From equation 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 assume that full time workers working 35 hours a week (7 hour a day for 5 working days) one worker working for 12 weeks wi ll 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 solve this we each employ more worker or ask the existing staff to do some extra over time when ever demand increaseFacilities and technologySince the sales forecast shows a high demand selecting the required facilities and technology in designing the manufacturing move for Weldon hand tools is very crucial therefore the first and foremost things to consider is the size of the facility and if there is room for expansion .the operation process and the required work forceWe need to have in place capital and labour, proper planning of the process, research on customer requirement, seminars and training to compete in the market as the sales forecast shows increase and decrease in demand and finally managing the inventory by having warehouse for the stocksAssembling smoothing plane can be divided into three major(ip) area, fly pressing, bench operation andwrapping, 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 discourse of tools and wrappingDesign layoutDesign layout is significant process in operation prudence ,the flow of the layout very much relies on the volume and variety characteristic which shapes the overall design (Slack et al, 2010).The decision as to which layout display case to adopt will be influenced by an understanding 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 according to its sales focus there is indication that this is high volume output 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 similar design with little variation, the design layout can be the same as the small variation does not affect the fundamental production process.Finally 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 minimum lead timeare the main The layout therefore can be organised in simple and flexible manner so as to enhance the speed 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 between the work stations. The operation will be organised such as each unit recovers the goods from the previous unit4.1- Layout constitutesS0 by numbering the element 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 cycle time, even though the cycle time for each quarter was shown in the above table in Fiq1, we will show the calculation of how it was arrive , but 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 will be = total volume /cycle time1.6/0.257 = 6.222= 7 stagesHaving known the number of stages we the n list the element 1-2 and draw the precedence draw to calculate the balancing lossElement 1 Assemble poke subassembly 0.12Element 2 harmonise poke subassembly to anuran 0.10Element 3 Rivet adjusting level to frog 0.15Element 4 Press adjusting nut screw 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 handle to base 0.17Element 9 Fit frog subassembly to base 0.15Element 10 Assemble trade name subassembly 0.08Element 11 Assemble blade subassembly,clamp and label to base and adjust 0.20Element 12 Make up box and wrap plane,pack and stock 0.20Fiq3below displays the final distribution of work after breaking down the process into different stages of the long thin gradement, the advantage is that its an ideal way of arranging flexible and expandable operation., makes moving and handling materials 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 8 jobless 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 toolfig2 group meeting 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 arr anged in 8 parallel 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 building where facilities are located, work plenty of space within the site hence enhancing easy expansion to meet increase in demand and finally the inventory will alike 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 encounter any competition of demand and capacityConclusionIn operational get outment 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 manufacturing process its desirable that the layout be design in a flexible way to rearrange stages that will create more populate 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 moment 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 promotion could improve the demand distribution to a smooth increase throughout the quarters.