$\backslash$table$[[$TASK$,$ELEMENT,TIME $($secs$)],[$A$,$Fit bearing hub for crank,$14],[$B$,$Fit front forks,$14],[$C$,$Mount wheels,$9],[$D$,$Attach the chain wheel to the crank,$5],[$E$,$Attach the chain wheel and crank to the frame,$9],[$F$,$Mount pedals,$3],[$G$,$Attach saddle,$9],[$H$,$Attach chain,$10],[$I$,$Fit handle bars,$9],[$J$,$Fit Brakes,$5],[$K$,$Fit stickers and inspect,$12],[$L$,$Pack into box,$12],[,,]]$

Table Q$1$a$($i$)$ Standard time for each task and build sequence

$\begin{array}{cc}\text{P}\text{e}\text{r}\text{i}\text{o}\text{d}& ?\\ \text{Y}\text{e}\text{a}\text{r}1& \text{U}\text{n}\text{i}\text{t}\text{s}\\ 1^{st}\text{q}\text{u}\text{a}\text{r}\text{t}\text{e}\text{r}& 98000\\ 2^{nd}\text{q}\text{u}\text{a}\text{r}\text{t}\text{e}\text{r}& 140000\\ 3^{rd}\text{q}\text{u}\text{a}\text{r}\text{t}\text{e}\text{r}& 140000\\ 4^{th}\text{q}\text{u}\text{a}\text{r}\text{t}\text{e}\text{r}& 230000\end{array}$

Table Q$1$a$($ii$)$ Sales forecast Year $1$ Question $2$

Instruction:

You must TYPE your answer by computer, using 'Times New Roman', font size $12$pt$.$ Only

MS Word format is accepted. Image file is not accepted. The MS Word file must

be submitted at "assignments" in Canvas.

The expected Word count and references for each part should be: $400-600$ words

plus $2-3$ Harvard references.

You must type your Name and Sunderland Student No$.$ on the cover page.

a$)$ The Directors of Spodleigh Bicycle Company are considering the introduction of Lean

Manufacturing to the plant but have number of queries about the concepts involved. As a

result they have requested that you write a short report which clearly explains the

following:

$($i$)$ What is the difference between 'push', 'pull' and 'Theory of constraints' approaches to

planning and control? Explain using diagrams, highlighting the pros and cons of each.

$(15$ marks$)$

$($ii$)$ What is 'level scheduling'? and what might be the pre$-$requisites before we can

introduce it$?$

$($Explain using diagrams where necessary$)$

$(10$ marks$)$

$($iii$)$ Will the 'Autocratic' culture of the company fit with the philosophy of 'Lean'? What

is the 'Lean Philosophy' in relation to people? and what 'working practices' need to

be put in place in order to move to a Lean environment?

$(10$ marks$)$

$($iv$)$ Recommend and describe a tool or technique which can be used to analyse and improve

the performance of 'Spodleigh' manufacturing systems e$.$g$.$ Rank$-$order clustering,

Ishikawa diagrams, value stream mapping etc, and explain its basic principle, how it

would be applied, the potential benefits and inhibitors to implementation

$(15$ marks$)$

$[$TOTAL $50$ marks$]$

End of AssignmentQuestion $1$

Instruction: Handwriting is allowed. The file must be submitted at "submission details" in

Canvas. You must write your Name and Sunderland Student No$.$ on the cover page.

a$)$ The Spodleigh Bicycle Company have developed a new bicycle called the 'Speedster'.

This is manufactured mainly from carbon fibre materials which means the cycle is

exceptionally light and fast $($See Figure Q$1$a $-$ parts view$).$ The marketing department

at Spodleigh are very excited about this new product and want to market it as soon as

possible. To facilitate this, they have produced a sales forecast for the new bicycles

and this is shown in Table Q$1$a$($ii$).$ The challenge for the Manufacturing group is to

design an assembly line configuration and determine, which option is most efficient

given the predicted sales forecast. Assuming staff work a $40$ hour week for $48$ weeks

per year you are required to determine the following:

i$)$ Design a product layout $($Long thin$)$ for the assembly operation which meets

the requirements of the $1$st quarter production

$(15$ Marks$)$

ii$)$ Using this layout, how many people are required to manufacture$/$assemble the

product? What is the balance loss and potential output of this arrangement?

$(6$ Marks$)$

iii$)$ If a 'short fat' layout is used in the $1^{st}$ quarter, how many people would be

required to assemble the products? What is the balance loss and potential

output of this arrangement?

$(8$ Marks$)$

iv$)$ Which layout is needed to meet the increasing demand in Year $1$ and why?

marks$)$

v$)$ What are the advantages and disadvantages of both 'long thin' and 'short fat'

layouts?

$(15$ Marks$)$

Q$1$a Component parts of the new 'Speedster'