A company is planning a new product line and a new factory to produce the parts and assemble the final products. The product line will include 10 different models. Annual production of each model is expected to be 1,000 units. Each product will be assembled of 300 components, but 75% of these will be purchased parts (not made in the new factory). There is an average of 8 processing operations required to produce each component, and each processing step takes 30 sec (including an allowance for setup time and part handling). Each final unit of product takes 48 min to assemble. All processing operations are performed at work cells that include a production machine and a human worker. Products are assembled at single workstations consisting of one worker each plus assembly fixtures and tooling. Each work cell and each workstation require 25 m^2 of floor space and an additional allowance of 50% must be added to the total production area for aisles, work-in-process storage, shipping and receiving, rest rooms, and other utility space.
1. The factory will operate one shift (the day shift, 2,000 hr/yr). Determine (a) how many processing and assembly operations, (b) how many workers (direct labor only), and (c) how much total floor space will be required in the plant.
2. Suppose the company is to operate three shifts (each 8 hours will have one shift, a total of 6,000 hr/yr) instead of one shift to accomplish the processing operations. The assembly of the product would still be accomplished on the day shift. Determine (a) how many processing and assembly operations, (b) how many workers on each shift (direct labor only), and (c) how much total floor space will be required in the plant.