Subject: Operations Management -1

Conceptual Exercise # 1 (Common to session 1 & 2)

Qus 1:
Prepare a process chart from the information below.

Expalin how a process chart could be used.

Data Given
Assembly Tasks fro Model D-41 Sharpener

Sr No Task Information Distance Moved

(in.)

1 Get motor and hold 20

2 Get Grinding assembly, attach to motor 24

3 Get base, attach motor and grinding assembly to base 24

4 Get housing, postion correctly 18

5 Get electric cord, insert into housing 12

Place housing unit beside base unit, connect electric

6 6
cord to motor.

7 Attach housing unit to base unit using three screws 12

8 Attach four ruber feet to base 15

9 Get shavings tray, insert into unit 20

10 Position unit, connect to electrical test. 12

 11 Wait for test, stop if unit fails and sound alarm

12 Place unit in package, close package, Place in chute 24

Prepare a process chart from the information below.

Ans :

Process Chart
Process for Assembly Task for Model D-41 Sharpener

Sr No Activity/Process Distance (in.)

1 Get motor and hold 20

2 Get Grinding assembly, attach to motor 24

3 Get base, attach motor and grinding assembly to base 24

4 Get housing, postion correctly 18

5 Get electric cord, insert into housing 12

Place housing unit beside base unit, connect electric

6 6
cord to motor.

7 Attach housing unit to base unit using three screws 12

8 Attach four ruber feet to base 15

9 Get shavings tray, insert into unit 20

10 Position unit, connect to electrical test. 12

11 Wait for test, stop if unit fails and sound alarm

 12 Place unit in package, Close package 24

13 Place in chute

Total distance
Total Process 187

Explain how a process chart could be used.

Ans :
1 To record the process happening at job floor

2 To record the sequance of process for a unit manufacturing

3 To understand distance travel by unit during its processing time

4 To understand the process time of a unit and factors find it.

5 To analyse the process for improvement in manufacturing process

6 To do reaserach and reduce the time required for a process to get complete

7 To plan the manufacturing shcedule as per time required and no of unit process in stipulated work per
Time Required
(Min)

0.05

0.08

0.12

0.05

0.07

0.1

0.25

0.15

0.06

0.08
 0.07

0.16

ss Chart

Operation Insepction Movement Delay Storage

Time (Min) Opeartion Quality check Transport In Que Storage
0.05 ü

0.08 ü

0.12 ü

0.05 ü

0.07 ü

0.1 ü

0.25 ü

0.15 ü

0.06 ü

0.08 ü

0.07 ü
 0.16 ü

Total time
1.24 11 1 0 0 1

cess in stipulated work period.

Subject: Operations Management -1

Conceptual Exercise # 1 (Common to session 1 & 2)

Qus 1:
Sweet Sound Speakers Company

The sweet sound speakers company (SSS) manufactures a variety of speakers for other companies that packag
One product made by SSS is K33 headphone speakers that are sold for use with portable radios and CD players
The production process involves assembling purchased components and subassemlies.
Dave Johnson, a production analyst at SSS, is analysing the production process for the K33 headphone to try to
Dave intends to draw an assembly chart and a process chart to show the current K33 production process.
He hopes these charts will help him to better understand the current production process and to develop improvem
The two tables below list the required components and the seembly steps to produce one unit of K33.

Component List for K33:

Predecessor
Sr No Component Description Component Component
Code Code(s)

1 Left speaker frame P14L

2 Right Speaker Frame P14R
3 Speaker S37 P14L, P14R
4 Wire Assembly W25 S37
5 faceplate F12 W25
6 Foam earpiece cover C44 F12
7 Metel center connector M11 C44

Assembly tasks for K33 Headphone Speakers:

Sr No Task Description Distance Worker

Moved Time
 (feet) (minutes)

1 Get components kit 12 0.2

2 Inspect that kit contains all parts 0.1
3 Inspect one speaker into left frame 3 0.1
4 Inspect one speaker into right frame 0.1
5 Attach wire to left speaker 4 0.1
6 Attach wire to right speaker 0.1
7 Inspect wire connections 4 0.1
8 Test sound quality 0.1
9 Snap faceplate on each frame 4 0.2
10 Put foam cover over each earpiece 4 0.2
11 Insert connector into both frames 4 0.2
12 Final inspection 4 0.2

Assignment
Prepare an assembly Chart for K33 Headphone assembly
Prepare a process chart for K33 headphone assembly
How might an assembly chart and process chart be helpful in indentifying improvemnts?

Ans :
Prepare an assembly Chart for K33 Headphone assembly

assembly Chart for K33 Headphone assembly

Predecessor
Sr Component Description Component Component
No Code Code(s)

1 Left speaker frame P14L

2 Right Speaker Frame P14R
3 Speaker S37 P14L, P14R
4 Wire Assembly W25 S37
5 faceplate F12 W25
6 Foam earpiece cover C44 F12
7 Metel center connector M11 C44
 P14L Left speaker frame
Inspection of Both Speaker
P14R Right Speaker Frame

S37 Speaker Inspection

W25 Wire Assembly Inspection of Wire connection

F12 faceplate Inspection of Sound Quality

C44 Foam earpiece cover Inspection of connector

M11 Metel center connector Final Inspection

Prepare a process chart for K33 headphone assembly

Process Chart for K33 Headphone

SSS compnay - K33 Headphone

Sr No Activity/Process Distance (feet)

1 Get components kit 12

2 Inspect that kit contains all parts

 3 Insert one speaker into left frame 3

4 Insert one speaker into right frame

5 Attach wire to left speaker 4

6 Attach wire to right speaker

7 Inspect wire connections 4

8 Test sound quality

9 Snap faceplate on each frame 4

10 Put foam cover over each earpiece 4

11 Insert connector into both frames 4

12 Final inspection 4

Total distance
Total Process 39

How might an assembly chart and process chart be helpful in indentifying improvemnts?

Ans :
Use of Assebmbly Chart

1 We get clear view of process under going for manufactuering of perticular unit

2 Useful for planning prodcution systems

3 Can be used for improvement in process & planning of a unit manucaturing process.
Process chart Use
1 To record the process happening at job floor

2 To record the sequance of process for a unit manufacturing

3 To understand distance travel by unit during its processing time

4 To understand the process time of a unit and factors find it.

5 To analyse the process for improvement in manufacturing process

6 To do reaserach and reduce the time required for a process to get complete

7 To plan the manufacturing shcedule as per time required and no of unit process in stipulated work per
er companies that package the speakers with their audio products.
ble radios and CD players.

e K33 headphone to try to indentify ways to produce the product more efficiently.
production process.
s and to develop improvement ideas.
ne unit of K33.

Quantity
Required

1
1
2
1
2
2
1
provemnts?

Quantity
Required

1
1
2
1
2
2
1
K33 Headphone

Operation Insepction Movement Delay Storage

Time (Min) Opeartion Quality check Transport In Que Storage
0.2 ü

0.1 ü
 0.1 ü

0.1 ü

0.1 ü

0.1 ü

0.1 ü

0.1 ü

0.2 ü

0.2 ü

0.2 ü

0.2 ü

Total time
1.7 8 4 0 0 0

ng improvemnts?
ess in stipulated work period.