WMS and Labor Estimate In-Class Case Study Duet January 31, 2020 A new stamping plant must supply an automotive final assembly plant with stampings. Each press is operated by I worker. For every 10 workers presses on duty there is a shift supervisor. In addition, there is a plant manager and administrative assistant for the plant The plant operates one 8 hours shift per day. 5 days per week, and 50 weeks per year. The plant is expected to produce a total of 50,000,000 stampings annually. However, 500 different stamping designs are required, in batch sims of 5000,0 each batch will be produced 20 times per year to minimize inventory. Each stamp takes 10 sec (cycle time) on average to produce. Before each batch, there is a set-up for the press with a standard time of 2.2 hours per set-up per bateh. Presses are reliable 96% during the stamping. Worker performance is 100% and the PFD Allowance is 18%. . 100 - In order to get the plant up and running, there will be one-week training for each press operator with a training cost of S1000 per employee. In addition, uniforms are issued to all press operators, supervisors and administrative assistants at a cost of $500 per employee. The average cost to on-board all new personnel (every working at the plant) is about $3200.00. . All workers on the presses are replaced when not at work. Supervisors, plant manager, and administrative assistants are considered fixed staffing. Non-productive time is 18% Benefits are 23% Hourly wages: Press operator - $18.50 o Supervisor - $25.64 O Plant Manager - $39.50 Administrative Assistant - $16.50 The company policy is to hire press operators as a .9 FTE to have flexibility in staffing during increased production periods. A partial FTE would be counted as 1 headcount. Fixed staffing is hired as a 1.0 FTE soooo, ooo shipping a ao Determine the following: 5ooo 1. # of presses that this new plant would need to purchase. 2. # of Productive, non-productive, and Paid FTEs requirements by position. 3. Headcount (# of employees) by position 4. Total Labor cost including training and onboarding. 5. Gross Hourly Cost for the plant. Submission Requirements: The deliverables needs to include answers to the five questions and tables showing your calculations. All of the analysis is to be done in Excel. Your excel spreadsheet must be submitted on Blackboard. WMS and Labor Estimate In-Class Case Study Duet January 31, 2020 A new stamping plant must supply an automotive final assembly plant with stampings. Each press is operated by I worker. For every 10 workers presses on duty there is a shift supervisor. In addition, there is a plant manager and administrative assistant for the plant The plant operates one 8 hours shift per day. 5 days per week, and 50 weeks per year. The plant is expected to produce a total of 50,000,000 stampings annually. However, 500 different stamping designs are required, in batch sims of 5000,0 each batch will be produced 20 times per year to minimize inventory. Each stamp takes 10 sec (cycle time) on average to produce. Before each batch, there is a set-up for the press with a standard time of 2.2 hours per set-up per bateh. Presses are reliable 96% during the stamping. Worker performance is 100% and the PFD Allowance is 18%. . 100 - In order to get the plant up and running, there will be one-week training for each press operator with a training cost of S1000 per employee. In addition, uniforms are issued to all press operators, supervisors and administrative assistants at a cost of $500 per employee. The average cost to on-board all new personnel (every working at the plant) is about $3200.00. . All workers on the presses are replaced when not at work. Supervisors, plant manager, and administrative assistants are considered fixed staffing. Non-productive time is 18% Benefits are 23% Hourly wages: Press operator - $18.50 o Supervisor - $25.64 O Plant Manager - $39.50 Administrative Assistant - $16.50 The company policy is to hire press operators as a .9 FTE to have flexibility in staffing during increased production periods. A partial FTE would be counted as 1 headcount. Fixed staffing is hired as a 1.0 FTE soooo, ooo shipping a ao Determine the following: 5ooo 1. # of presses that this new plant would need to purchase. 2. # of Productive, non-productive, and Paid FTEs requirements by position. 3. Headcount (# of employees) by position 4. Total Labor cost including training and onboarding. 5. Gross Hourly Cost for the plant. Submission Requirements: The deliverables needs to include answers to the five questions and tables showing your calculations. All of the analysis is to be done in Excel. Your excel spreadsheet must be submitted on Blackboard