ClockSports.com Manufacturing Processes: Golf Clock Baseball Clock Process # P15001 P15002 P15003 P15004 P12001 P12002 P12003 P12004 P11001 P11002 P11003 P11004 P11005 Process Step Turn Brass Base Turn Golfball Install Clock Inspect and Package Turn Brass Base Turn Baseball Install Clock Inspect and Package Fill Tennisball Turn Brass Base Turn Tennisball Install Clock Inspect and Package Machine Required Hardinge Cobra 42 Hardinge Cobra 42 Assembly Bench Assembly Bench Hardinge Cobra 42 Hardinge Cobra 65 Assembly Bench Assembly Bench Model 345 TBF Hardinge Cobra 42 Hardinge Cobra 65 Assembly Bench Assembly Bench Setup Number Standard Time Raw Material Required 15698 1.72 min 3" Brass Round Stock 15555 0.98 min. Topflight XL 15002 0.33 min. Clock Mechanism 15002 0.15 min. Packaging 12333 1.98 min 3" Brass Round Stock 12789 1.28 min. Rawlings 200 12489 0.33 min. Clock Mechanism 12489 0.15 min. Packaging 11588 3.10 min. Polymer 11569 2.72 min 3" Brass Round Stock 11444 0.98 min. Spalding 100 11458 0.33 min. Clock Mechanism 11458 0.15 min. Packaging Tennis Clock Sales Forecast Estimated Total Yearly Requirment Golf Clock Baseball Clock Tennis Clock 887,173 208,712 979,897 2014 Set-up Time Information Set up Number 15698 15555 15002 12333 12789 12489 11588 11569 11444 11458 Machine Standard Time for Setup Hardinge Cobra 42 28 minutes Hardinge Cobra 42 33 minutes Assembly Bench 5 minutes Hardinge Cobra 42 26 minutes Hardinge Cobra 65 41 minutes Assembly Bench 5 minutes Model 345 TBF 98 minutes Hardinge Cobra 42 28 minutes Hardinge Cobra 65 | 26 minutes Assembly Bench 5 minutes 75% 95% TBD Company Information Typical Efficiency Typical Machine Reliability Shift Schedule Cost Estimates Model 345 TBF Hardinge Cobra 42 Hardinge Cobra 65 Assembly Bench $ $ 152,000 48,500 58,200 897 $ ys ciou NY -3p MY 1 2. Review the Sports Clock process and Excel file with volume, process times, setup times, etc. This is the description of your manufacturing system. Note. For this analysis assume that scrap rates are negligible. a) Determine how your manufacturing operation will be set up (cells, process departments, or product departments). Also, determine what your shift schedule will be identify your holiday and vacation plans). [5 points) b) Develop a simple process flow diagram for your operation(s). 15 points) c) Calculate the equipment fraction for each process step. Based on how the manufacturing operation is set up determine the number of machines required to meet next year's production forecast. [15 points) Formula for machine fractions: F-SQ/EHR Where F= number of machines required per shift S = standard time (minutes) per unit produced Q-number of units to be produced per shift E- actual performance, expressed as percentage of standard time H amount of time (minutes) available per machine R reliability of machine, expressed as percent of uptime Machine Fractions Solution Number Required Cost Standard Time Set up Number Machine for Setup 15698 Hardlinge Cobra 42 25 minutes 10006 Hardinge Cobra 42 33 minutes 15002 Assembly Bench 5 minutes 12333 Hardinge Cobra 4226 minutes 12789 Hardinge Cobra 65 1 minutes 12489 Assembly Bench 6 minutes 1188 Model 346 TBF 98 minutes 11569 Hardinge Cobra 42 28 minutes 11444 Hardinge Cobra 65 26 minutes 11458 Assembly Bench 6 minutes ClockSports.com Manufacturing Processes: Golf Clock Baseball Clock Process # P15001 P15002 P15003 P15004 P12001 P12002 P12003 P12004 P11001 P11002 P11003 P11004 P11005 Process Step Turn Brass Base Turn Golfball Install Clock Inspect and Package Turn Brass Base Turn Baseball Install Clock Inspect and Package Fill Tennisball Turn Brass Base Turn Tennisball Install Clock Inspect and Package Machine Required Hardinge Cobra 42 Hardinge Cobra 42 Assembly Bench Assembly Bench Hardinge Cobra 42 Hardinge Cobra 65 Assembly Bench Assembly Bench Model 345 TBF Hardinge Cobra 42 Hardinge Cobra 65 Assembly Bench Assembly Bench Setup Number Standard Time Raw Material Required 15698 1.72 min 3" Brass Round Stock 15555 0.98 min. Topflight XL 15002 0.33 min. Clock Mechanism 15002 0.15 min. Packaging 12333 1.98 min 3" Brass Round Stock 12789 1.28 min. Rawlings 200 12489 0.33 min. Clock Mechanism 12489 0.15 min. Packaging 11588 3.10 min. Polymer 11569 2.72 min 3" Brass Round Stock 11444 0.98 min. Spalding 100 11458 0.33 min. Clock Mechanism 11458 0.15 min. Packaging Tennis Clock Sales Forecast Estimated Total Yearly Requirment Golf Clock Baseball Clock Tennis Clock 887,173 208,712 979,897 2014 Set-up Time Information Set up Number 15698 15555 15002 12333 12789 12489 11588 11569 11444 11458 Machine Standard Time for Setup Hardinge Cobra 42 28 minutes Hardinge Cobra 42 33 minutes Assembly Bench 5 minutes Hardinge Cobra 42 26 minutes Hardinge Cobra 65 41 minutes Assembly Bench 5 minutes Model 345 TBF 98 minutes Hardinge Cobra 42 28 minutes Hardinge Cobra 65 | 26 minutes Assembly Bench 5 minutes 75% 95% TBD Company Information Typical Efficiency Typical Machine Reliability Shift Schedule Cost Estimates Model 345 TBF Hardinge Cobra 42 Hardinge Cobra 65 Assembly Bench $ $ 152,000 48,500 58,200 897 $ ys ciou NY -3p MY 1 2. Review the Sports Clock process and Excel file with volume, process times, setup times, etc. This is the description of your manufacturing system. Note. For this analysis assume that scrap rates are negligible. a) Determine how your manufacturing operation will be set up (cells, process departments, or product departments). Also, determine what your shift schedule will be identify your holiday and vacation plans). [5 points) b) Develop a simple process flow diagram for your operation(s). 15 points) c) Calculate the equipment fraction for each process step. Based on how the manufacturing operation is set up determine the number of machines required to meet next year's production forecast. [15 points) Formula for machine fractions: F-SQ/EHR Where F= number of machines required per shift S = standard time (minutes) per unit produced Q-number of units to be produced per shift E- actual performance, expressed as percentage of standard time H amount of time (minutes) available per machine R reliability of machine, expressed as percent of uptime Machine Fractions Solution Number Required Cost Standard Time Set up Number Machine for Setup 15698 Hardlinge Cobra 42 25 minutes 10006 Hardinge Cobra 42 33 minutes 15002 Assembly Bench 5 minutes 12333 Hardinge Cobra 4226 minutes 12789 Hardinge Cobra 65 1 minutes 12489 Assembly Bench 6 minutes 1188 Model 346 TBF 98 minutes 11569 Hardinge Cobra 42 28 minutes 11444 Hardinge Cobra 65 26 minutes 11458 Assembly Bench 6 minutes