Case Problem - Ingco Industrial Tools Ingco Industrial Tools, is one of the most successful subsidiary tool manufacturers, has decided to move into the "woodworking' tools market. Previously, its products had been confined to car maintenance, home decorating and general hand tools. One of the first products that it decided to manufacture was a general-purpose 'smoothing plane', a tool that smooths and shapes wood. Its product designers devised a suitable design, and the company's work measurement engineers estimated the time it would take (in standard minutes) to perform each work element in the assembly process. The marketing department also estimated the likely demand (for the whole Philippine market) for the new product. Its sales forecast is shown in the Table 1 below. However, a substantial proportion of demand is likely to be export sales, which we find difficult to predict. But whatever demand does turn out to be, we will have to react quickly to meet the demand from the customers. The more we enter this part of the market, the more we are into impulse buying and the more sales we lose if we don't supply. It has been decided by the Ingco management to use the calculated forecast data for January 2023 results using linear trend approach without seasonality in order to be conservative as December forecast is expected to be in downward trend as a basis in the planning of workforce, equipment, and raw materials and etc., whenever possible. This plane was likely to be the first of several similar planes. Another model had already been approved for launch about 1 year after this, and two or three other models were in the planning stage. All the planes were similar, merely varying in length and width.Table 1 - Sales for smoothing plane Year 2022 Production Volume [Units) Jan 32000 Feb 32000 Mar 34000 Apr 44000 May 46000 Jun 50000 Jul 46000 Aug 44000 Sept 50000 Oct 65000 Nov 60000 Dec 45000 Note: Use the nearest whole value of thousands when forecasting demand for January 2023 Designing the manufacturing operation facility It has been decided to assemble all planes at one of the company's smaller factory sites where a whole workshop is unused. Within the workshop, there is plenty of room for expansion if demand proves to be higher than that forecasted. All machining and finishing of parts would be performed at this main factory and the parts shipped to the smaller site, where they would be assembled at the available workshop. An idea of the assembly task can be gained from the partially exploded view of the product (see the figure). In Table 2 gives the 'standard time' for each element of the assembly task. Some of the tasks are described as "fly press' operations. A fly press is a relatively simple tool, about a meter high, which has two weights mounted onto a screw thread. When the two weights are rotated, they give momentum to the downward action of the screw thread, which applies a downward force. This force is used for simple bending, riveting or force-fitting operations. A fly press is not an expensive or sophisticated piece of technology. This fly press will approximately occupy a space of 1square meter.Figure 1: The Parts of a Plane Blade (iron) Lateral Chip- Lever adjustment breaker cap lever Apply oil to screws and bearing points. Polish top to help clean Depth shavings. adjustment knob Polish back face Dress Poke Frog of blade and edge to fit hone level. breaker. Dress edge to Handle mate with blade. Sand frog Tote face flat to Sand frog contact Plane Tuning Key seat blade. points to fit body. Level 1 - Check this first. Repairs almost Frog adjusting always needed. screw Level 2 - Check this next Repairs may be needed. Body Level 3 - Check this last. Repairs may Mouth Knob not be needed. Flatten sole. (throat) File mouth to remove burrs Lightly chamfer and/or fit thicker blade. edges. Figure 2: Parts of the Plane Tate- SIDE SECTION VIEW Lever cap- Frog Position chipbreaker adjusting " from the edge of screw - the blade Adjust frog for narrow throat opening- TOP VIEW Frog Hone blade to a Chipbreaker -slightly crowned profile "Cap iron NOTE: Crown exaggerated Iron (Blade)Table 2: Standard time for each element of assembly task in standard minutes (SM) Element Element of Task Time in No. standard minutes (SM] Press operations Assemble poke subassembly (LH poke, RH poke, poke 0.12 bush) 2 Fit poke subassembly to frog (poke S/A, poke pin, frog) 0.10 3 Rivet adjusting lever to frog (adjusting lever, rivet, frog) 0.15 4 Press adjusting nut screw to frog (frog, adjusting nut 0.08 screw) Total Time 0.45 Bench operations 5 Fit adjusting nut to frog 0.15 6 Fit frog screw to frog 0.05 7 Fit knob to base 0.15 8 Fit handle (Tole) to base 0.17 Fit frog subassembly to base 0.15 10 Assemble blade subassembly 0.08 11 Assemble blade subassembly, clamp and label to base 0.20 and adjust 12 Make up box and wrap plane, pack and stock Total Time 7 There are 12 elements in the process and standard times for each element of assembly task in standard minutes (SM). However, element 12 is in the process of time and motion study where the results are on Table 3, where the operations analyst rated worker at 85% where worker performed 85% of the normal time and the firm uses allowance factor is 15%. (Used this formula for Standard Time= Normal Time/ (1-Allowance Factor) Table 3: Time and Motion Study of Element 12 Observations 2 3 4 5 Total Time (Minutes) |0.18 0.22 0.17 0.23 20Ill. Production Plan/ Schedule. (Mark 15 points) Shows how the production schedule is calculated showing the production forecast in a table. You may include a graphical trend line to show the behavior of the forecast. The calculated January 2023 forecast must be clear. IV. Process Flow Diagram. (Tasks/Work Elements) (Mark 15 points) Depict/ draw the process flow diagram of all the processes or (tasks/ work elements) how the product is produced. Label them correctly and use the appropriate symbols. V. Takt Time, Cycle Time, Throughput Time, Capacity Calculation. (Mark 15 points) 1. Here, you must compute the required take time, cycle time/process times, throughput time, total work time, normal time, standard time, showing how line is balance. 2. Use the diagram in item IV., label them, and indicate the computed standard time per work elements (in minute/unit), total task time/work elements (in minute per unit) and its corresponding output per work elements (units/hour) and total task time/work elements (units/hour), and capacity of production if balance (units/hour). VI. Manpower Projections Calculation. (Mark 15 points) 1. Proceed to compute for the number resources/ workers required based on item V. I would like you to assume to have a production run of one (1) shift operations six (6) days in week to start production in January 2 to January 31, 2023. 2. Determine the calculated efficiency of the line. 3. Using the same diagram in item IV or V., balance the line and indicate the number of required resources by using an icon of a worker. 4. Allocate the tasks correspondingly. Vil. Facility Layout Configuration. (Mark 15 points) Design a facility layout or configuration for the assembly operation (to include press work) including the tasks to be performed at each part of the system and put them together in a diagram showing an icon of the worker and/or equipment on how the resources is arranged using the different types of layout configuration you learned from this course based on the case facts. Estimate the size of the facility