a)Smoothtools manufacturing company want to enter the woodworking tools market and one of the first products it has decided to manufacture is a general purpose smoothing plane. (See Figure Q1a - parts view). After reverse engineering the wood plane, the planning department have arrived at a build sequence and timings for each task which is shown in Table Q1a (i). Furthermore, the marketing department at Smoothtools have produced a sales forecast for the new planes. This is shown in Table Q1a(ii)]. Assuming staff work a 35 hour week for 48 weeks per year you are required to determine the following: i)Design a product layout (Long thin) for the assembly operation (including the fly press) which meets the requirements of the 1st quarter production (15 Marks) ii)Using this layout, how many people are required to manufacture/assemble the product? What is the balance loss and potential output of this arrangement? (6 Marks) iii)If a short fat layout is used in the 1st quarter, how many people would be required to assemble the products? What is the balance loss and potential output of this arrangement?

iv)Which layout is needed to meet the increasing demand in Year 1 and why?

(6 (6 Marks)

(8 Marks)

v)What are the advantages and disadvantages of both long thin and short fat layouts? (15 Marks)

Figure Q1a Exploded view of wood plane

TASK ELEMENT TIME (Seconds) PRESS OPERATIONS A Build poke sub-assembly 7 secs B Fit poke assembly to frog 6 secs C Rivet adjusting lever to frog 9 secs D Press adjusting nut screw to frog 5 secs TOTAL PRESS OPERATIONS 27 secs BENCH OPERATIONS E Fit adjusting nut to frog 9 secs F Fit frog screw to frog 3 secs G Fit knob to base 9 secs H Fit handle to base 10 secs I Fit frog sub-assembly to base 9 secs J Assemble blade sub-assembly 5 secs K Assemble blade sub-assembly , clamp and label to base and adjust/inspect 12 secs L Make up box and wrap plane, pack and stock 12 secs TOTAL ASSEMBLY AND PACK TIME 69 secs Table Q1a(i) Standard time for each task and build sequence

Period Year 1 Units 1st quarter 98000 2nd quarter 140000 3rd quarter 140000 4th quarter 230000 Table Q1a(ii) Sales forecast Year 1