A new stamping plant must supply an automotive final assembl

A new stamping plant must supply an automotive final assembly plant with stampings, and y the number of new stamping presses must be determined. Each press will be operated by one worker. The plant will operate one 8-hour shift per day. five days per week, 50 weeks per year The plant must produce a total of 20,000,000 stampings annually. However, 400 different stamping designs are required, in batch sizes of 5000 each, so each batch will be produced 10 times per year to minimize build-up of inventory. Each stamping takes 6 sec on average to produce. Scrap rate averages 2% in this type of production. Before each batch, the press must be set up. with a standard time per setup of 3.0 hours. Presses are 95% reliable (avail-ability - 95%) during production and 100% reliable during setup. Worker efficiency is expected to be 100%. How many new stamping presses and operators will be required?

Solution

400 stamping designs will be produced 10 times each so total production batches =4000

Total hours per person per press =8*5*50=2000 hrs

Each press set up takes 3 hr so total set up time =12000 hrs

20,000,0000 stampings needed as scrap rate is 2% total stampings needed =20,000,000/.98= 20,408,164

Timefor production= 34014 hrs @ 6 sec per stamping

Total time =12000+34014= 46014

Total no of operators needed =46014/2000 = 23

No of stamping press required =400/.95 =421