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A forging press plant must be planned to manufacture engine components as per the details given. Parts are placed in the furnace an hour prior to forging; they are then removed, forged, and trimmed one at a time. The complete cycle takes 3 min per part. Each time a new batch is started, the forging cell must be changed over, which consists of changing the forging and trimming dies for the next part style. This takes 4 hr on average. Applicable direct labor rate in that location is RM50 per hour, factory overhead rate on labor = 30%; capital investment in machine = RM750,000; rate of return = 10%; and applicable factory overhead rate on machine = 25%. The plant will operate 24 hriday, 5 days/week, 50 weekslyear. Total output from the plant must be 800,000 forgings per year in batches of 1000 parts per batch. Assume scrap rate as 3%. i For the above conditions, recommend the number of forging press cells that would be required for in the new plant. State reasons and assumptions if any, in your recommendation ii. Due to pandemic situation if the plant is operated only 1 shift/day in a year, discuss the consequences on the hourly rate of work center. Propose the mitigation plan required to maintain the plant capacity at 100% with minimum additional investment. What is the change in hourly rate if 2 shifts/day are allowed, after the mitigation plan?

A forging press plant must be planned to manufacture engine components as per the details given. Parts are placed in the furnace an hour prior to forging; they are then removed, forged, and trimmed one at a time. The complete cycle takes 3 min per part. Each time a new batch is started, the forging cell must be changed over, which consists of changing the forging and trimming dies for the next part style. This takes 4 hr on average. Applicable direct labor rate in that location is RM50 per hour, factory overhead rate on labor = 30%; capital investment in machine = RM750,000; rate of return = 10%; and applicable factory overhead rate on machine = 25%. The plant will operate 24 hriday, 5 days/week, 50 weekslyear. Total output from the plant must be 800,000 forgings per year in batches of 1000 parts per batch. Assume scrap rate as 3%. i For the above conditions, recommend the number of forging press cells that would be required for in the new plant. State reasons and assumptions if any, in your recommendation ii. Due to pandemic situation if the plant is operated only 1 shift/day in a year, discuss the consequences on the hourly rate of work center. Propose the mitigation plan required to maintain the plant capacity at 100% with minimum additional investment. What is the change in hourly rate if 2 shifts/day are allowed, after the mitigation plan?

Elements Of Electromagnetics
Elements Of Electromagnetics
7th Edition
ISBN:9780190698614
Author:Sadiku, Matthew N. O.
Publisher:Sadiku, Matthew N. O.
ChapterMA: Math Assessment
Section: Chapter Questions
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A forging press plant must be planned to manufacture engine components as per the details given. Parts are placed in the furnace an hour prior to forging; they are then removed, forged, and trimmed one at a time. The complete cycle takes 3 min per part. Each time a new batch is started, the forging cell must be changed over, which consists of changing the forging and trimming dies for the next part style. This takes 4 hr on average. Applicable direct labor rate in that location is RM50 per hour, factory overhead rate on labor = 30%; capital investment in machine = RM750,000; rate of return = 10%; and applicable factory overhead rate on machine = 25%. The plant will operate 24 hr/day, 5 days/week, 50 weeks/year. Total output from the plant must be 800,000 forgings per year in batches of 1000 parts per batch. Assume scrap rate as 3%. i. For the above conditions, recommend the number of forging press cells that would be required for in the new plant. State reasons and assumptions if any, in your recommendation ii. Due to pandemic situation if the plant is operated only 1 shift/day in a year, discuss the consequences on the hourly rate of work center. Propose the mitigation plan required to maintain the plant capacity at 100% with minimum additional investment. What is the change in hourly rate if 2 shifts/day are allowed, after the mitigation plan?
Transcribed Image Text:A forging press plant must be planned to manufacture engine components as per the details given. Parts are placed in the furnace an hour prior to forging; they are then removed, forged, and trimmed one at a time. The complete cycle takes 3 min per part. Each time a new batch is started, the forging cell must be changed over, which consists of changing the forging and trimming dies for the next part style. This takes 4 hr on average. Applicable direct labor rate in that location is RM50 per hour, factory overhead rate on labor = 30%; capital investment in machine = RM750,000; rate of return = 10%; and applicable factory overhead rate on machine = 25%. The plant will operate 24 hr/day, 5 days/week, 50 weeks/year. Total output from the plant must be 800,000 forgings per year in batches of 1000 parts per batch. Assume scrap rate as 3%. i. For the above conditions, recommend the number of forging press cells that would be required for in the new plant. State reasons and assumptions if any, in your recommendation ii. Due to pandemic situation if the plant is operated only 1 shift/day in a year, discuss the consequences on the hourly rate of work center. Propose the mitigation plan required to maintain the plant capacity at 100% with minimum additional investment. What is the change in hourly rate if 2 shifts/day are allowed, after the mitigation plan?
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