Mfg Ops-3e-S 11-22, 23/06, 06/04/07

Chapter 2 MANUFACTURING OPERATIONS

REVIEW QUESTIONS
2.1 What is manufacturing? Answer !"# $efiniti#ns are gi%en in the te&t, #ne techn#'#gica' an$ the #ther ec#n#mic. !he techn#'#gica' $efiniti#n is the f#''#"ing Manufacturing is the app'icati#n #f ph(sica' an$ chemica' pr#cesses t# a'ter the ge#metr(, pr#perties, an$/#r appearance #f a gi%en starting materia' t# ma)e parts #r pr#$ucts* manufacturing a's# inc'u$es the +#ining #f mu'tip'e parts t# ma)e assem,'e$ pr#$ucts. !he ec#n#mic $efiniti#n is the f#''#"ing Manufacturing is the transf#rmati#n #f materia's int# items #f greater %a'ue ,( means #f #ne #r m#re pr#cessing an$/#r assem,'( #perati#ns. 2.2 What are the three ,asic in$ustr( categ#ries? Answer !he three ,asic in$ustr( categ#ries are the f#''#"ing -1. /rimar( in$ustries, "hich are th#se that cu'ti%ate an$ e&p'#it natura' res#urces, such as agricu'ture an$ mining* -2. sec#n$ar( in$ustries, "hich c#n%ert the #utputs #f the primar( in$ustries int# pr#$ucts* the( inc'u$e manufacturing, c#nstructi#n, an$ p#"er generati#n* an$ -3. tertiar( in$ustries, "hich c#nstitute the ser%ice sect#r #f the ec#n#m(, "hich inc'u$es ,an)ing, retai', transp#rtati#n, e$ucati#n, gi%ernment, an$ s# #n. 2.3 What is the $ifference ,et"een c#nsumer g##$s an$ capita' g##$s? Answer: 0#nsumer g##$s are pr#$ucts that are purchase$ $irect'( ,( c#nsumers, such as cars, pers#na' c#mputers, !1s, tires, t#(s, an$ tennis rac)ets. 0apita' g##$s are pr#$ucts purchase$ ,( #ther c#mpanies t# pr#$uce g##$s an$ supp'( ser%ices. 2&amp'es inc'u$e c#mmercia' aircraft, mainframe c#mputers, machine t##'s, rai'r#a$ e3uipment, an$ c#nstructi#n machiner(. 2.4 What is the $ifference ,et"een a pr#cessing #perati#n an$ an assem,'( #perati#n? Answer 4 pr#cessing #perati#n transf#rms a "#r) materia' fr#m #ne state #f c#mp'eti#n t# a m#re a$%ance$ state that is c'#ser t# the fina' $esire$ part #r pr#$uct. 5t a$$s %a'ue ,( changing the ge#metr(, pr#perties, #r appearance #f the starting materia'. 4n assem,'( #perati#n +#ins t"# #r m#re c#mp#nents t# create a ne" entit(, ca''e$ an assem,'(, su,assem,'(, #r s#me #ther term that refers t# the +#ining pr#cess. 2.6 7ame the f#ur categ#ries #f part-shaping #perati#ns, ,ase$ #n the state #f the starting "#r) materia'. Answer !he f#ur categ#ries are -1. s#'i$ificati#n pr#cesses, -2. particu'ate pr#cessing, -3. $ef#rmati#n pr#cesses, an$ -4. materia' rem#%a' pr#cesses. 2.6 4ssem,'( #perati#ns can ,e c'assifie$ as permanent +#ining meth#$s an$ mechanica' assem,'(. What are the f#ur t(pes #f permanent +#ining meth#$s? Answer !he +#ining pr#cesses are -1. "e'$ing, -2. ,ra8ing, -3. s#'$ering, an$ -4. a$hesi%e ,#n$ing. 2.7 What is the $ifference ,et"een har$ pr#$uct %ariet( an$ s#ft pr#$uct %ariet(? Answer 9ar$ pr#$uct %ariet( is "hen the pr#$ucts $iffer su,stantia''(. 5n an assem,'e$ pr#$uct, har$ %ariet( is characteri8e$ ,( a '#" pr#p#rti#n #f c#mm#n parts am#ng the pr#$ucts* in man( cases, there are n# c#mm#n parts. S#ft pr#$uct %ariet( is "hen there are #n'( sma'' $ifferences ,et"een pr#$ucts. !here is a high pr#p#rti#n #f c#mm#n parts am#ng assem,'e$ pr#$ucts "h#se %ariet( is s#ft. 2.: What t(pe #f pr#$ucti#n $#es a +#, sh#p perf#rm? Answer ;#" pr#$ucti#n #f specia'i8e$ an$ cust#mi8e$ pr#$ucts. !he pr#$ucts are t(pica''( c#mp'e&, such as space capsu'es, aircraft, an$ specia' machiner(. 2.< ='#" 'ine pr#$ucti#n is ass#ciate$ "ith "hich #ne #f the f#''#"ing 'a(#ut t(pes -a. ce''u'ar 'a(#ut, -,. fi&e$p#siti#n 'a(#ut, -c. pr#cess 'a(#ut, #r -$. pr#$uct 'a(#ut? Answer -$. /r#$uct 'a(#ut. 2.10 What is the $ifference ,et"een a sing'e-m#$e' pr#$ucti#n 'ine an$ a mi&e$-m#$e' pr#$ucti#n 'ine? Answer 4 sing'e-m#$e' pr#$ucti#n 'ine ma)es pr#$ucts that are a'' i$entica'. 4 mi&e$-m#$e' pr#$ucti#n 'ine ma)es pr#$ucts that ha%e m#$e' %ariati#ns characteri8e$ as s#ft pr#$uct %ariet(. 2.11 What is meant ,( the term technological processing capability ? 3

Mfg Ops-3e-S 11-22, 23/06, 06/04/07 Answer !echn#'#gica' pr#cessing capa,i'it( #f a p'ant -#r c#mpan(. is its a%ai'a,'e set #f manufacturing pr#cesses. 5t inc'u$es n#t #n'( the ph(sica' pr#cesses, ,ut a's# the e&pertise p#ssesse$ ,( p'ant pers#nne' in these pr#cessing techn#'#gies. 2.12 What is 'ean pr#$ucti#n? Answer !he $efiniti#n gi%en in the te&t is the f#''#"ing ;ean pr#$ucti#n means #perating the fact#r( "ith the minimum p#ssi,'e res#urces an$ (et ma&imi8ing the am#unt #f "#r) that is acc#mp'ishe$ "ith these res#urces. ;ean pr#$ucti#n a's# imp'ies c#mp'eting the pr#$ucts in the minimum p#ssi,'e time an$ achie%ing a %er( high 'e%e' #f 3ua'it(, s# that the cust#mer is c#mp'ete'( satisfie$. 5n sh#rt, 'ean pr#$ucti#n means $#ing m#re "ith 'ess, an$ $#ing it ,etter. 2.13 5n 'ean pr#$ucti#n, "hat is +ust-in-time $e'i%er( #f parts? Answer 4s $efine$ in the te&t, +ust-in-time $e'i%er( #f parts refers t# the manner in "hich parts are m#%e$ thr#ugh the pr#$ucti#n s(stem "hen a se3uence #f manufacturing #perati#ns is re3uire$ t# ma)e them. 5n the i$ea' +ust-in-time s(stem, each part is $e'i%ere$ t# the $#"nstream "#r)stati#n imme$iate'( ,ef#re that part is nee$e$ at the stati#n. 2.14 5n 'ean pr#$ucti#n, "hat $#es "#r)er in%#'%ement mean? Answer 4s e&p'aine$ in the te&t, "#r)er in%#'%ement means that "#r)ers are assigne$ greater resp#nsi,i'ities an$ are pr#%i$e$ "ith training that a''#"s them t# ,e f'e&i,'e in the "#r) the( can $#. 4's#, "#r)ers participate in pr#,'em-s#'%ing e&ercises t# a$$ress issues face$ ,( the c#mpan( 2.16 5n 'ean pr#$ucti#n, "hat $#es c#ntinu#us impr#%ement mean, an$ h#" is it usua''( acc#mp'ishe$? Answer 0#ntinu#us impr#%ement in%#'%es an unen$ing search f#r "a(s t# ma)e impr#%ements in pr#$ucts an$ manufacturing #perati#ns. 5t is usua''( acc#mp'ishe$ ,( "#r)er teams "h# c##perate t# $e%e'#p s#'uti#ns t# pr#$ucti#n an$ 3ua'it( pr#,'ems.

PROBLEMS
2.1 4 p'ant pr#$uces three pr#$uct 'ines 4, >, an$ 0. !here are 6 m#$e's "ithin pr#$uct 'ine 4, 4 m#$e's "ithin >, an$ : "ithin 0. 4%erage annua' pr#$ucti#n 3uantities #f each 4 m#$e' is 600 units, 700 units f#r each > m#$e', an$ 1100 units f#r each 0 m#$e'. ?etermine the %a'ues #f -a. P an$ -,. Qf f#r this p'ant. Solution -a. !he parameter P is the t#ta' num,er #f $ifferent pr#$uct m#$e's pr#$uce$. P @ 6 A 4 A : @ 1: $ifferent m#$e's. -,. Qf is the t#ta' pr#$ucti#n 3uantit( #f a'' pr#$ucts ma$e in the fact#r(. Qf @ 6-600. A 4-700. A :-1100. @ 3000 A 2:00 A ::00 @ 14,600 units 2.2 !he 4>0 0#mpan( is p'anning a ne" pr#$uct 'ine an$ "i'' ,ui'$ a ne" p'ant t# manufacture the parts f#r a ne" pr#$uct 'ine. !he pr#$uct 'ine "i'' inc'u$e 60 $ifferent m#$e's. 4nnua' pr#$ucti#n #f each m#$e' is e&pecte$ t# ,e 1000 units. 2ach pr#$uct "i'' ,e assem,'e$ #f 400 c#mp#nents. 4'' pr#cessing #f parts "i'' ,e acc#mp'ishe$ in #ne fact#r(. !here are an a%erage #f 6 pr#cessing steps re3uire$ t# pr#$uce each c#mp#nent, an$ each pr#cessing step ta)es 1.0 minute -inc'u$es an a''#"ance f#r setup time an$ part han$'ing.. 4'' pr#cessing #perati#ns are perf#rme$ at "#r)stati#ns, each #f "hich inc'u$es a pr#$ucti#n machine an$ a human "#r)er. 5f each "#r)stati#n re3uires a f'##r space #f 260 ft2, an$ the fact#r( #perates #ne shift -2000 hr/(r., $etermine -a. h#" man( pr#$ucti#n #perati#ns, -,. h#" much f'##rspace, an$ -c. h#" man( "#r)ers "i'' ,e re3uire$ in the p'ant. Solution !his pr#,'em neg'ects the effect #f assem,'( time. -a. nof @ PQnpno @ 60-1000.-400.-6. @ 120 000 000 operations in the fact#r( per (ear. -c. !#ta' #perati#n time @ -120 & 106 #ps.-1min./-60 min./hr.. @ 2,000,000 hr/(r. 4t 2000 h#urs/(r per "#r)er, w @

2,000,000hr / (r @ 1000 wor!ers. 2000hr / "#r )er

-,. 7um,er #f "#r)stati#ns n @ w @ 1000. !#ta' f'##rspace @ -1000 stati#ns.-260 ft2/stati#n. @ 2"0 000 #t2 2.3 !he BCD 0#mpan( is p'anning t# intr#$uce a ne" pr#$uct 'ine an$ "i'' ,ui'$ a ne" fact#r( t# pr#$uce the parts an$ assem,'( the fina' pr#$ucts f#r the pr#$uct 'ine. !he ne" pr#$uct 'ine "i'' inc'u$e 100 $ifferent m#$e's. 4nnua' pr#$ucti#n #f each m#$e' is e&pecte$ t# ,e 1000 units. 2ach pr#$uct "i'' ,e assem,'e$ #f 600 c#mp#nents. 4'' pr#cessing #f parts an$ assem,'( #f pr#$ucts "i'' ,e acc#mp'ishe$ in #ne fact#r(. !here are an a%erage #f 10 pr#cessing steps re3uire$ t# pr#$uce each c#mp#nent, an$ each pr#cessing step ta)es 30 sec. 4

Mfg Ops-3e-S 11-22, 23/06, 06/04/07 -inc'u$es an a''#"ance f#r setup time an$ part han$'ing.. 2ach fina' unit #f pr#$uct ta)es 3.0 h#urs t# assem,'e. 4'' pr#cessing #perati#ns are perf#rme$ at "#r) ce''s that each inc'u$es a pr#$ucti#n machine an$ a human "#r)er. /r#$ucts are assem,'e$ #n sing'e "#r)stati#ns c#nsisting #f t"# "#r)ers each. 5f each "#r) ce'' an$ each "#r)stati#n re3uire 200 ft2, an$ the fact#r( #perates #ne shift -2000 hr/(r., $etermine -a. h#" man( pr#$ucti#n #perati#ns, -,. h#" much f'##rspace, an$ -c. h#" man( "#r)ers "i'' ,e re3uire$ in the p'ant. Solution -a. Qf @ PQ @ 100-1000. @ 100,000 pr#$ucts/(r 7um,er #f fina' assem,'( #perati#ns @ 100 000 as$% ops&%r 7um,er #f pr#cessing #perati#ns nof @ PQnpno @ 100-1000.-600.-10. @ '00 000 000 pro( ops&%r -c. !#ta' pr#cessing #perati#n time @ -600 & 106 #ps.-0.6 min./-60 min./hr.. @ 6,000,000 hr/(r. !#ta' assem,'( #perati#n time @ -100 & 103 as,( #ps.-3 hr/pr#$uct. @ 300,000 hr/(r !#ta' pr#cessing an$ assem,'( time @ 6,300,000 hr/(r 4t 2000 h#urs/(r per "#r)er, w @

6,300,000hr / (r @ 2'"0 wor!ers . 2000hr / "#r )er

-,. With 1 "#r)er per "#r)stati#n f#r pr#cessing #perati#ns, n @ w @ 2600 @ 2600 "#r)stati#ns. With 2 "#r)ers per stati#ns f#r assem,'(, n @ "/2 @ 160/2 @ 76 "#r)stati#ns. !#ta' f'##r space 4 @ -2676 stati#ns.-200 ft2/stati#n. @ "1" 000 #t2 2.4 5f the c#mpan( in /r#,'em 2.3 "ere t# #perate three shifts -6000 hr/(r. instea$ #f #ne shift, $etermine the ans"ers t# -a., -,., an$ -c.. Solution -a. Same t#ta' num,er #f pr#cessing an$ assem,'( #perati#ns ,ut sprea$ #%er three shifts. 7um,er #f fina' assem,'( #perati#ns @ 100 000 as$% ops&%r 7um,er #f pr#cessing #perati#ns nof @ PQnpno @ 100-1000.-600.-10. @ '00 000 000 operations&%r -c. Same t#ta' num,er #f "#r)ers re3uire$ ,ut sprea$ #%er three shifts. !#ta' "#r)ers " @ 2'"0 wor!ers. 7um,er #f "#r)ers/shift @ w/3 @ ::3.33 ))* wor!ers&shi#t. -,. 7um,er #f "#r)ers f#r pr#cessing #perati#ns @ 2600/3 @ :33 "#r)er per shift -::4 #n #ne shift. 7um,er #f "#r)ers f#r assem,'( @ 160/3 @ 60 "#r)ers per shift. 7um,er #f "#r)stati#ns n @ :33 A 60/2 @ :6: -:6< #n #ne #f the shifts.. Esing the higher num,er, !#ta' f'##r space A @ -:6< stati#ns.-200 ft2/stati#n. @ 1+1 )00 #t2