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Q 2 . ( Power Toys ) PowerToys Inc. produces a small remote - controlled toy truck on a con - veyor belt with nine
QPower Toys PowerToys Inc. produces a small remotecontrolled toy truck on a con veyor belt with nine stations. Each station has, under the current process layout, one worker assigned to it Stations and processing times are summarized in the following table: Station Task Mount battery units Insert remote control receiver Insert chip Mount from axle Mount back axle Install electric motor Connect motor to battery unit Connect motor to rear axle Mount plastic body Processing Times seconds a What is the bottleneck in this process? b What is the capacity, in toy trucks per hour, of the assembly line? c What is the direct labor cost for the toy truck with current process if each worker re ceives $hour expressed in dollars per toy truck? d What would be the direct labor cost for the toy truck if work would be organized in a work cell, that is one worker performs all tasks? Assume that the processing times would remain unchanged ie there are not specialization gains e What is the utilization of the worker in station Because of a drastically reduced forecast, the plant management has decided to cut staffing from nine to six workers per shift. Assume that i the nine tasks in the preceding table can not be divided; ii the nine tasks are assigned to the six workers in the most efficient way possible; and iii if one worker is in charge of two tasks, the tasks have to be adjacent ie one worker cannot work on tasks and f How would you assign the nine tasks to the six workers? g What is the new capacity of the line in toy trucks per hour
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