solve them
Course: SCMT 4200 Individual Assignment “Execution and Control of Operations Problems” Due Date: Monday, April 4, 2021 (Week 12) – 11:59 pm Delivery: Uploaded to Assignment Drop Box in DC Connect Save the assignment files into your own workspace (USB, hard drive) Before you submit the final version, rename the document as follows: “SCMT 4200 Individual Assignment your name_last 4 digits of your student ID” For example: SCMT 4200 Individual Assignment Skelton 1234 Weighting: 15% of the final grade in this course.Total Marks: _________ / 100 Student Name: ____________________________ Student ID #: ________________ Description: Solve the problems on the following pages, using techniques and concepts that have been, or will be presented in classes. Typed answers are preferred, but neatly handwritten / printed answers are acceptable if they can be read easily. Use the spaces provided to answer the questions. Show your work. Within the first seven weeks of this semester, students ought to be able to answer the questions shown in Section A. In Weeks 8 through 11, students will be equipped with the tools to answer questions shown in Section B. When you have completed this assignment, save a copy using the naming convention as prescribed above, and upload it into the Assignment Drop Box in DC Connect. Section A Problem # 1 (10 marks) Use this space to show your calculations: Problem # 2 (10 marks) A toy company has an order for 1000 of a toy car Item # 02-2619 for delivery on Day 80 on the shop calendar. The toy car consists of the following parts: Subassembly A is a frame. When combined with a Subassembly B, a chassis, the toy car # 02-2619 will be completed. The frame subassembly A requires 3 components: an unfinished shell (component X), a window kit (component Y) and a door kit (component Z). The following are the work centers and times for each operation. Using a piece of graph paper, draw a backward schedule (operation setback chart) based on the information provided. For one mark of the ten available in this question, when must Component Z be scheduled to start production to meet the delivery date? See the next page for the Operations and standard times for each. Assume that all components and subassemblies move through the process in lots of 1,000. The start day for Component Z will need to be Day # _________________. (1 mark of the 10 for this question) Part Operation Standard Time (Days) X 10 2 20 4 Y 30 3 40 5 Z 50 6 60 3 Subassembly A 5 Subassembly B 70 2 80 4 Final Assembly Toy Car 2 Problem 3 (5 marks) Complete the following input/output report. What are the planned and actual backlogs at the end of Period 5? Period 1 2 3 4 5 Total Planned Input 78 78 78 78 78 Actual Input 80 84 74 82 80 Cumulative Variance X Period 1 2 3 4 Total Planned Output 80 80 80 80 80 Actual Output 83 82 78 80 84 Cumulative Variance X Period 1 2 3 4 5 Total Planned Backlog 45 X Actual Backlog 45 X Problem 4: (5 marks) Using the information in the following route file, open order file, and MRP planned orders, calculate the load on the work center. (5 marks) Routing: Part 2345: Setup time= 2 standard hours Run time per piece= 4 standard hours per piece Part 1166: Setup time= 3 standard hours Run time per piece= 0.5 standard hour per piece Open Orders for Parts Planned Orders for Parts Week 1 2 3 1 2 3 Part 2345 14 9 6 5 5 10 Part 1166 16 6 5 4 10 15 Load Report Week >>> 1 2 3 Released Load 2345 1166 Planned Load 2345 1166 Total Load Problem 5: (5 marks) A work center has the following open and planned orders for a given week. Calculate the total standard time required (load) (5 marks): Order Qty Setup Time (hours) Run Time (hours) Total Time (hours) Released Orders Part # A111 380 1.50 0.10 Part # B222 240 3.00 0.30 Planned Orders Part # C333 360 2.50 0.25 Part # D444 440 2.00 0.15 Total Time (standard hours) Problem 6. (10 marks) a. Lear Corporation in Ajax assembles car seats for Fiat Chrysler in Brampton, Ontario. Assume that the company makes the seats in two varieties: leather and fabric. The standard labour hours for these are 1.2 and 1.0 hours, respectively. The seats are made in two work centers, sewing and assembly, where the average percentage of work has been 55 percent for sewing and 45 percent for assembly. Given the following schedule for the next six weeks, calculate the labour hours needed in each of the two work centers. Week 1 2 3 4 5 6 Leather 15 20 18 21 15 13 Fabric 65 60 62 59 65 67 Use these tables to express your answers: Sewing Assembly 0.55 0.45 Leather 1.2 Fabric 1.0 Week 1 2 3 4 5 6 Sewing Assembly b. Following up on part (a.) above, what are the average labour hours needed over the 6-week period? Calculate the largest variances from the average. Does this look like a serious problem to you? If so, how would you recommend handling these variances from a staffing perspective? Average labour hours: Sewing: ________________hours Largest variance: __________ hours Assembly: ______________hours Largest variance: __________ hours Comment: c. Again, following up on part 6 (a.) above, the leather requires incoming inspection for each car seat to be sure that the colours match. The time required for this is 5 minutes per seat. What are the expected capacity requirements for the inspection department over the next six weeks? Week 1 2 3 4 5 6 Minutes Hours Hints for completing Problem 6: Question 6 can be a challenge and requires some critical thinking. If you are struggling with this question, or need the confidence that you have taken the right approach, let me provide a few hints to get you started: In Question 6, We are told that it will take 1.2 standard hours to manufacture a leather seat. 55% of that time is spent in sewing. Therefore, each leather seat has to spend 1.2 standard hours x 55% = 0.66 of a standard hour in sewing. We are told that it takes 1 standard hour to manufacture 1 fabric seat. 55% of that time will be spent in sewing. Therefore, each fabric seat has to spend 1 standard hour x 55% = 0.55 of a standard hour in sewing. We must manufacture 15 leather seats in Week 1 15 seats x 0.66 standard hours = 9.9 hours are needed in sewing for the leather seats We must manufacture 65 fabric seats in Week 1 65 seats x 0.55 standard hours = 35.75 hours are needed in sewing for the fabric seats Add the 9.9 hours required for the leather seats to the 35.75 hours needed for the fabric seats together, therefore we will need 9.9 + 35.75 = 45.65 hours of time in the sewing department to meet the Production Schedule. So I have shown you how to compute the number of hours required for sewing in week 1. Use the same approach for every other week for sewing. Then, compute the same numbers for Assembly, for each of the 6 weeks. See the chart below, taken from the question itself, and look at the numbers in red.) You can fill in the rest and go from there! Problem 7 (5 marks) Curtis, the Production Manager at Martin Machine Company, is preparing a production schedule for one of the fabrication shop’s machines, the Monster Metal Lathe. He has collected the following information on jobs currently waiting to be processed at this machine. (There are no other jobs, the machine is empty, and the shop is operational 7 days per week.). Job Machine Processing