Consider the manufacture of a simple remote control, constructed of five components; the top cover, bottom cover,

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Consider the manufacture of a simple remote control, constructed of five components;

the top cover, bottom cover, circuit board, keypad, and battery compartment cover.

The top cover is molded, which produces 5% scrap. Labels are painted on the top cover, of which 95% of the completed top covers are acceptable. The keypad is molded (5% scrap) and painted (2% scrap). The top cover and keypad are assembled together with a circuit board purchased from an outside vendor. The current subassembly is tested, and 10% fail. As a result, the circuit boards are scrapped, but the keypad and top cover assembly are used until a circuit board passes. The bottom cover is molded, of which 10% of moldings are scrapped, and those that pass are snapped to the top cover–keypad–circuit board assembly. The remote is tested again; this time only 3% fail. On those that fail, the remote is disassembled. The disassembly process causes 75% of bottom covers to be scrapped. The circuit boards are also scrapped.

Those assemblies that are acceptable are combined with the battery compartment cover. The battery compartment cover is molded, and 8% are scrapped. Find the input quantities required to produce 10,000 remotes.

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Facilities Planning

ISBN: 9780470444047

4th Edition

Authors: James A. Tompkins, John A. White, Yavuz A. Bozer, J. M. A. Tanchoco

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