Answered Essay: There are 18 injection molding machines on the floor of a small company. The shop

There are 18 injection molding machines on the floor of a small company. The shop produces batches of molded parts requiring a setup time of 2.8 hours for each production batch. Average standard time for each part in a batch is 35 seconds, and there are an average of 400 parts in a batch. The plant workforce consists of three workers per molding machine, one foreman, plus two clerical support staff. (a) Determine how many molded parts can be produced in 1 month, if there are 8 hours worked per day and an average of 22 days per month at one shift per day. (b) What is the labor productivity ratio of the molding floor, expressed as parts per worker-hour?

Expert Answer

The total time to produce one full batch in one machine = 2.8 hours + (400 x 35 / 3600) hours = 6.689 hours
Total time available considering 18 machines = 18 x 8 x 22 hours = 3168 hours

So, number of batches that can be produced = 3168 / 6.689 = 473.6

So, number of parts that can be produced = 473.6 x 400 = 189,449 parts —————–(a)

Total worker hours = (3 x 18 x 8 x 22) + (1 x 8 x 22) + (2 x 8 x 22) = 57 x 8 x 22 = 10032 hours

Labor productivity = 189449 / 10032 = 18.88 parts per worker-hour —————-(b)

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