Question: Operations Management – Gaither- Chapter 4- Sweet Sound

Speakers Company (Pg-159 -160)

Given,

Component List for K23

S No Component Component Predecessor Quantity

Description Code Component Required
Code(s)
1 Left speaker P14L - 1
Frame
2 Right speaker P14R - 1
frame
3 Speaker S37 P14L,P14R 2
4 Wire assembly W25 S37 1
5 Faceplate F12 W25 2
6 Foam earpiece C44 F12 2
cover
7 Metal canter M11 C44 1
connector

Assembly Task for K33 Headphone speaker

SNo Task Description Distance Worker

Moved( feet) Time( minutes)
1 Get component kit 12 0.2
2 Inspect that kit - 0.1
contains all part
3 Insert one speaker 3 0.1
into left frame
4 Insert one speaker - 0.1
into right frame
5 Attach wire to left 4 0.1
speaker
6 Attach wire to right - 0.1
speaker
7 Inspect wire 4 0.1
connections
8 Test sound quality - 0.1
9 Snap face plate on 4 0.2
each frame
10 Put Foam cover over 4 0.2
each earphone
11 Insert connector into 4 0.2
both frames
12 Final inspection 4 0.2
 SA- Sub Assembly
A -Assembly
Assembly Chart
I- Inspection

Component kit: P14L, P14R, S37, W25, F12, C44 &M11)

1

P14L Inspection of all component kits I-1

2

SA-1
S37
3

SA-2
P14R
4

W25 Assemble of frames, speaker & frame

5 A-1

Inspection wire connections I-2

Test sound quality I-3

F12 Snap face plate on each frame

6 A-2

C44 Put Foam cover over each earphone

7 A-3

M11 Insert connector into both frames

8 A-4

Process Flow Chart

Final inspection I-4
 Distance Worker
SNo Symbols Task Description Process
Moved( feet) Time( minutes)
1 Get component Operations 12 0.2
kit
2 Inspect that kit Inspection - 0.1
contains all part
3 Insert one speaker Operations 3 0.1
into left frame
4 Insert one speaker Operations - 0.1
into right frame
5 Attach wire to left Operations 4 0.1
speaker
6 Attach wire to right Operations - 0.1
speaker
7 Inspect wire Inspection 4 0.1
connections
8 Test sound quality Inspection - 0.1

9 Snap face plate on Operations 4 0.2

each frame
10 Put Foam cover Operations 4 0.2
over each
earphone
11 Insert connector Operations 4 0.2
into both frames
12 Final inspection Inspection 4 0.2

Summary

SL No Symbol Process No of times Distance Working

moved( feet) time(Mins)
1 Operations 8 31 1.2

2 Transport

3 Delay

4 Inspection 4 8 0.5
5 Store

Total 39 1.7
Hence, Total operation time TO =1.2 minutes and Cycle time Tc = 1.7 Minutes
Question: Operations Management – Gaither- Chapter 4- Exercise 8
(Pg-156 - 157)
 Process chart is the overview of all the material or components, sub-assemblies,
inspection, assemblies of a production system which showing the sequence of the
flow of a production process by way of recording all activities and events under
review with appropriate symbols. This chart uses symbols of operation,
transportation, inspection, delay and storage. The distances moved and operation
times are also recorded along the symbols side .

Process chart
Distance Worker
SNo Symbols Task Description Process
Moved( feet) Time( minutes)
1 Get the motor and Operations 20 0.05
hold
2 Get grinding Operations 24 0.08
assembly, attach
the motor
3 Get base, attach Operations 24 0.12
motor and grinding
assembly to base
4 Get housing, Operations 18 0.05
position correctly
5 Get electric cord, Operations 12 0.07
insert into housing
6 Place housing unit Operations 6 0.10
beside base unit,
connect electric
cord to motor
7 Attach housing unit Operations 12 0.25
to base unit using
screws
8 Attach four rubber Operations 15 0.15
feet to base
9 Get shaving tray, Operations 20 0.06
insert into unit
10 Position unit, Inspection 12 0.08
connect to
electrical test
11 Wait for test, stop if Delay 0.07
unit fails and sound
alarm
12 Place unit in Operations 24 0.16
package, close
package, place in
chute
Summary

SL No Symbol Process No of times Distance Working

moved( feet) time(Mins)
1 Operations 10 175 1.09

2 Transport

3 Delay 1 0.07

4 Inspection 1 12 0.08
5 Store

Total 187 1.24

From the process chart analysis,

Operation Time, To = 1.09 minutes

Cycle Time, Tc = 1.24 minutes.

The process chart is very useful to reduce cycle time by simplification,

rearranging and combining assembly tasks.

For example

 Combine assembly of base along with motor, grinding, housing,

electric cord, four rubber feet unit together.
 Rearrange the position of the shavings tray and inspection unit to
minimize the distance moved.
 The delay for manual intervention of inspection unit can be minimize
by upgrading reliable automation.