Your objective is to review the feasibility of a project for your company, Huskie Fabrication. The potential customer manufactures soft drink dispensing equipment and has won a large contract to provide equipment for convenience stores all across the country. Your process engineer has reviewed the blueprints for the job and created a Bill of Material and process routings for each part. This is an individual project and is to be completed after Section $2$ Lesson $2$ and before moving on to Section $2$ Lesson $3.$Your job is to do the $$macro$$ manufacturing planning by reviewing the documents and provide the deliverable items as listed in the document. Show your work. If Excel is used, submit the file including formulas. If Word is used, submit the Word file$\mathrm{.}1.$ Create an Operations Chart for the frame assembly $($similar to Fig $5\mathrm{.}2$ in your book$).30$ pts$.$a$.$ Include operation numbers and rate data.b$.$ A hand$-$drawn chart is fine.c$.$ Calculate total hours for $1000$ frames, show at the bottom$\mathrm{.}2.$ Create Process Charts $($fig$.5-3$A$)$ for each of the components that make up the entire assembly by tracingtheir path through the process from raw material to its$$ final destination. This includes the Base Pan Assembly. There is only one of these forms in this packet $$ you will have to print a chart for each of the components. $20$ pts$.$a$.$ It might help to first create a Flow Diagram $($see instructions in bullet point $3$ below$)($fig$.5\mathrm{.}1$ in textbook$),$ tovisualize the flow of each component from department to department.b$.$ Start with the raw material location, include all wait instances, travel instances, operations, etc.c$.$ Using the scale on the drawing $(1=20),$ calculate the distance each part is traveling and enter this distance in the chart $($the $$Distance in Feet$$ column$).$ This can be done with a ruler for distance in inches $$then multiply by the scale on the drawing. Remember that parts in a factory travel by aisles, not necessarily in a straight line between two points. Assume that the component is traveling from the center of the department is in to the center of the department it is going to$.$ Record this distance for each move.d$.$ Fill in the columns in the $$Details of Process$$ section to the best of your ability, including the $$Time Hrs$/$Unit$$and $$Cost per Unit$$ columns. Use a labor rate of $$21$ per hour for the cost column.e$.$ Because your factory is departmentalized and is taking a batch approach, assume a $$wait$$ occurs at each operation.

f$.$ Also due to the $$batch$$ approach, assume that all components are traveling together $($do not multiply the travel distance by the number of components$).$g$.$ Note and record movements from department to department$\mathrm{.}3.$ Using the supplied plant layout, create one Flow Diagram $($fig$.5\mathrm{.}1),$ showing the flow of each component. Try to keep this clean and differentiate each line somehow $$ a color for each part number, etc. Track each item until it stops flowing as a component. $($Once it converts into an assembly, i$.$e$.$ Base Pan Assembly, the flow stops for the component and it is continued as the assembly. There should only be one line heading out of the shipping dock!$10$ pts$\mathrm{.}4.$ Using the data from your Operations Chart, determine the labor cost for each item and total labor cost of entire frame assembly. Assume the labor rate of $$21$ per hour. Pay attention to the quantities of each component used on the frame! $10$ pts$\mathrm{.}5.$ Calculate the takt time for frames based on a customer demand of $95$ frames per day. $10$ pts$.$a$.$ Assume $(2)8-$hour shifts $16$ hours $$ with no breaks. Breaks already factored into rates.b$.$ Use rates on routing sheets as is $$ they are already factored for breaks, fatigue, etc$\mathrm{.}6.$ Based on the labor data and assuming you are already at $100\%$ capacity, determine the total number of new hires $($additional employees$)$ required to complete $23,750$ frames per year $(95$ frames per day, $5$ days per week, $50$weeks per year$).10$ pts$.$a$.$ Employee hours$=8$ hours X $5$ days X $50$ weeks$\mathrm{.}7.$ Based on rate data and $23,750$ frames per year, calculate the number of machines required, assuming $(2)8-$hour shifts. Again, pay close attention to how many of each part is required for the assembly! $10$ pts$.$a$.$ Powder coat operation has plenty of capacity.b$.$ List of machines:$1.$ Shear$2.$ CNC Punch$3.$ Press Brake $($Form operation$)4.$ Manual Punch Press$5.$ CNC Drill $($drill operation$)6.$ CNC Tap $($tap operation$)7.$ Resistance Welder $($spot weld operation$)8.$ Band Saw $($saw operation$)9.$ Nibbler $($notch operation$)10.$ Welder$8.$ Note any suggestions for improvement.