Answer:
a) Rp= 200,000 / (50 X 10 X 8)= 50.0 units /hr
b) Tc= E/Rp= 60 (0.95) /50 =1.14 min
Ts= Tc - Tr = 1.14 - 0.15 = 0.99 min
w= Min Int > Twc/EbTs= 15.0 X 60 / (0.93 X 0.99) ) 944.5 rounded: 978 workers /shift
Total number of workers = 1956 over 2 shifts
n= w/M = 978/2.2 = 444.3 rounded 445 stations
Annual workload WL = 200,000 cars x 15/hr/car = 3,000,000 hr/work
with 1956 workers,= 1956 (50 X 10 X 8) = 3,912000 hr
This doesn´t include E, Eb and Er
E= 0.95 (given), Eb= 0.93 and Er= 0.99/1.14= 0.8684
Usable service time: 3, 912,000 (0.95) (0.93( (0.8684) = 3,912,000(0.767) = 3,001, 409 hr
C) the plant operates (50 weeks/yr)(10 shifts/week) (8 hr(shift) = 4000 hr/yr
Total hourly labor rate= $30 + $15= $45/hr
total labor cost = (1956 workers) (2000 hr/wrk-yr) ($45/hr) = $176,040,000
LAbor cost in trim-chassis-final per car= 176,040,000/200,000 = $880.20/car
