#1: Swiss Watch Problem The Swiss Watch Corporation manufactures watches on a co
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Question
#1: Swiss Watch Problem
The Swiss Watch Corporation manufactures watches on a conveyor belt with six stations. One worker stands at each station and performs the following tasks:
Station
Tasks
Processing Time (seconds)
Preparation 1
Heat-stake lens to bezel
Inspect bezel
Clean switch holes
Install set switch in bezel
Total time for A
14
26
10
20
70
Preparation 2
Check switch travel
Clean inside bezel
Install module in bezel
Total time for B
23
20
25
23+20+25=
Battery installation
Install battery clip on module
Heat-stake battery clip on module
Install 2 batteries in module
Check switch
Total time for C
20
15
22
13
70
Band installation
Install band
Inspect band
Total time for D
45
15
60
Packaging preparation
Cosmetic inspection
Final test
Total time for E
20
55
75
Watch packaging
Place watch and cuff in display box
Place cover in display box base
Place owner’s manual, box into tub
Total time for F
20
10
30
60
a. Calculate production capacity for all resources. What is the bottleneck in this process?
b. What is the capacity, in watches per hour, of the assembly line?
c. Assuming all workers are paid at rate of $15.00 per hour per worker, what is the average labor cost for assembling one watch (in the long term)?
d. Assuming demand is more than the process capacity, what are the utilizations of the six workers?
e. How many minutes of idle time will the worker in station C have in one hour?
f. These six workers begin their workday at 8:00a.m. and work steadily until 4:00p.m. at 4:00p.m., no new watch parts are introduced into station A and the conveyor belt continues until all of the work-in-process inventory has been processed and leaves station F. Thus, each morning the workers begin with an empty system. What time will it be (round to minute) when the assembly line has processed 150 watches on any given day?
Station
Tasks
Processing Time (seconds)
Preparation 1
Heat-stake lens to bezel
Inspect bezel
Clean switch holes
Install set switch in bezel
Total time for A
14
26
10
20
70
Preparation 2
Check switch travel
Clean inside bezel
Install module in bezel
Total time for B
23
20
25
23+20+25=
Battery installation
Install battery clip on module
Heat-stake battery clip on module
Install 2 batteries in module
Check switch
Total time for C
20
15
22
13
70
Band installation
Install band
Inspect band
Total time for D
45
15
60
Packaging preparation
Cosmetic inspection
Final test
Total time for E
20
55
75
Watch packaging
Place watch and cuff in display box
Place cover in display box base
Place owner’s manual, box into tub
Total time for F
20
10
30
60
Explanation / Answer
assume that working time of per worker is 8 hour per day part-a Calculatation of production capacity for all resources station total second per day time taken for process (in second) production per day Preparation 1 28800 70 411.43 Preparation 2 28800 68 423.53 Battery installation 28800 70 411.43 Band installation 28800 60 480.00 Packaging preparation 28800 75 384.00 Watch packaging 28800 60 480.00 b. capacity, in watches per hour, of the assembly line? station total second per day time taken for process (in second) production per day production per hour Preparation 1 28800 70 411.43 51.43 Preparation 2 28800 68 423.53 52.94 Battery installation 28800 70 411.43 51.43 Band installation 28800 60 480.00 60.00 Packaging preparation 28800 75 384.00 48.00 Watch packaging 28800 60 480.00 60.00 c. all workers are paid at rate of $15.00 per hour per worker, what is the average labor cost for assembling one watch (in the long term)? station laour hour per day wage rate total wage production per day average labor cost Preparation 1 8 15 120.00 411.43 0.29 Preparation 2 8 15 120.00 423.53 0.28 Battery installation 8 15 120.00 411.43 0.29 Band installation 8 15 120.00 480.00 0.25 Packaging preparation 8 15 120.00 384.00 0.31 Watch packaging 8 15 120.00 480.00 0.25 d Assuming demand is more than the process capacity than we can incease production by double shift of worker is possiable by 100% use of resouses e Idle time is unproductive time on the part of employees or machines as a result of factors beyond their control. Idle time is the time associated with waiting, or when a piece of machinery is not being used but could be. Idle time could also be associated with computing, and in that case refers to processing time. idle time for C station in second time taken by A station for process 70 plus time taken by B station for process 68 idle tine In second 138.00 idle tine In minuts 2.30 station time taken for process idle time total time taken Preparation 1 70 70 140.00 Preparation 2 68 70 138.00 Battery installation 70 138 208.00 Band installation 60 208 268.00 Packaging preparation 75 268 343.00 Watch packaging 60 343 403.00 403.00 1500.00 in minute 25.00 total minutes for 150 watches =150*25 3750.00
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