Question

1. There are 20 forging presses in the forge shop of a small company. The shop produces batches of forgings requiring a setup time of 3.0 hours for each production batch/machine. Average standard time for each part in a batch is 45 seconds, and there are 600 parts in a batch/machine. The plant workforce consists of two workers per press, two foreman, plus three clerical support staff. (a) Determine how many forged parts can be produced in 1 month, if there are 8 hours worked per day and average of 21 days per month at one shift per day. (b) What is the labor productivity ratio of the forge shop, expressed as parts per worker-hour

Answer 1

Answer:

The solution according to the given scenario is described below.

Explanation:

The given values are:

No. of foreign presses,

= 20

Required setup time,

= 3 hours

Average standard time,

= 45 seconds

Average produced batch,

= 600

Now,

(a)

The number of workers will be:

= $20\times 2+2+3$

= $40+2+3$

= $45$

The total time for batch's production will be:

= $3\times 60+(45\times \frac{600}{60} )$

= $180+45\times 10$

= $630 \ minutes$

or

= $10.5 \ hours$

The total number of hours per month will be:

= $8\times 21$

= $168 \ hours$

then,

The total batches per month will be:

= $\frac{168}{10.5}$

= $16 \ batches \ per \ month$

Total batches = $20\times 16$

                       = $320$

Now,

The produced pieces will be:

= $320\times 600$

= $192000 \ pieces/month$

(b)

$Labour \ productivity= \frac{ Total \ production}{ Labour \ hours }$

On substituting the given values, we get

                                $=\frac{192000}{(8\times 21\times 45)}$

                                $=25.4 \ per \ worker \ hours$