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A manual arc-welding cell uses two operators: a welder and a fitter (who lays out, positions, and secures parts and assemblies according to specifications). The
A manual arc-welding cell uses two operators: a welder and a fitter (who lays out, positions, and secures parts and assemblies according to specifications). The cell operates 2600hr/yr. The welder is paid $33/hr and the fitter is paid $24/hr. Both rates include applicable overheads. The cycle time to complete one welded assembly is 16.6 min. Of this time, the arc-on time is 26%, and the fitter's participation in the cycle is 9% of the cycle time. A robotic arc-welding cell is being considered to replace this manual cell. The new cell would have one robot, one fitter, and two workstations, so that while the robot is working at the first station, the fitter is unloading the other station and loading it with new components. The fitter's rate would remain at $24/hr. For the new cell, the production rate would be 7 welded assemblies per hour. The arc-on time would increase to almost 57%, and the fitter's participation in the cycle would be about 55%. The installed cost of the robot and workstations is $143,000. Power and other utilities to operate the robot and arc welding equipment will be $3.8/hr, and annual maintenance costs are $3000. Given a 5 -year service life, 16% rate of return, and no salvage value, determine the annual quantity of welded assemblies (nearest integer) that would have to be produced to reach the breakeven point for the two methods. 3,956 margin of error +/1%
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