Teaching Notes

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Reading: Tour De Force

Answer to questions

1. The Viper/Prowler assembly plant is much smaller than typical automobile assembly plants. The plant covers 392,000 square feet of space as opposed to other typical auto assembly plants that cover from 2 million square feet to 5 million square feet of space.
The production capacity of the Viper plant is much less than a typical automobile assembly line. The Viper plant's daily production capacity is 13 Vipers and 20 Prowlers compared to large automobile assembly plants that can manufacture 1000 vehicles per day.

While most large automobile plants require 2000 or more workers, the Viper plant employs only 260 employees.

The Viper plant employs skilled "craftsman" workers. Typical auto assembly plants use workers to do repetitive work with little skill required.

There are no robots or automation in the Viper plant while most auto assembly plants have high levels of automation.

The Viper plant uses early 20th century manual assembly techniques on two manual, parallel, relatively short (12 work stations and 720 feet long) assembly lines with generous idle time built in. Typical assembly lines usually involve the use of robots, large number of workstations and very little idle time.

2. The reasons for not having robots or other high level automation include the following:

Chrysler Corporation wants to portray a high quality image of two handcrafted automobile models that is generally more expensive and appealing to high-income individuals. The personal attention to the customers is part of the marketing package associated with both products.

Operations Tour: Hi-Bek Precision Spring Co. Ltd.

Answers to questions

1. Job shop, because every job is different and production is based on customer order of their specific design. However, the process flows are rather similar for all the jobs..

2. Because Hi-Bek carries inventories of various types and gauges of raw material (wires), and a large amount of WIP in order to efficiently schedule and use its equipment and workers.

3. Yes, the layout groups various machines of the same type together. Most jobs follow the sequences shown on the layout below. As it can be observed, the movement of material is usually minimized (especially if WIP is stored for a while, given that inventory is kept in the middle). However, for Job B, requiring grinding and then finishing, there is excessive material handling. The location of grinding is chosen so that the dust from it is contained in the corner of the shop. Perhaps finishing operations can be moved closer to the shipping gates in order to reduce material handling and throughput time.

Instructor’s Manual, Chapter 6
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