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Assignment 1

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23 views2 pages

Assignment 1

Uploaded by

janafarid902
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Assignment 1

Question (1)
A certain job shop specializes in one-of-a-kind orders dealing with parts of medium-to-high
complexity. A typical part is processed sequentially through ten machines in batch sizes of one.
The shop contains a total of eight conventional machine tools and operates 35 hours per week of
production time. The machine tools are interchangeable in the sense that they can be set up for
any operation required on any of the parts. The average time values on the part are machining
time per machine = 0.5-hour, work handling time per machine = 0.3 hour, tool change time per
machine = 0.2 hour, setup time per machine = 6 hours, and nonoperation time per machine = 12
hours. A new programmable machine has been purchased by the shop that can perform all ten
operations in a single setup. The programming of the machine for this part will require 20 hours;
however, the programming can be done off-line, without tying up the machine. The setup time
will be 10 hours. The total machining time will be reduced to 80% of its previous value due to
advanced tool control algorithms; the work handling time will be the same as for one machine;
and the total tool change time will be reduced by 50% because it will be accomplished
automatically under program control. For the one machine, nonoperation time is expected to be
12 hours. (a) Determine the manufacturing lead time for the traditional method and for the new
method. (b) Compute the plant capacity for the following alternatives: (i) a job shop containing
the eight traditional machines, and (ii) a job shop containing two of the new programmable
machines. Assume the typical jobs are represented by the data given above. (c) Determine the
average level of work-in-process for the two alternatives in part (b), if the alternative shops
operate at full capacity.
Question (2)
A factory produces cardboard boxes. The production sequence consists of three operations: (1)
cutting, (2) indenting, and (3) printing. There are three machines in the factory, one for each
operation. The machines are 100% reliable and operate as follows when operating at 100%
utilization: (1) In cutting, large rolls of cardboard are fed into the cutting machine and cut into
blanks. Each large roll contains enough material for 4,000 blanks. Production cycle time = 0.03
minute/blank during a production run, but it takes 35 minutes to change rolls between runs. (2) In
indenting, indentation lines are pressed into the blanks to allow the blanks to later be bent into
boxes. The blanks from the previous cutting operation are divided and consolidated into batches
whose starting quantity = 2,000 blanks. Indenting is performed at 4.5 minutes per 100 blanks.
Time to change dies on the indentation machine = 30 min. (3) In printing, the indented blanks are
printed with labels for a particular customer. The blanks from the previous indenting operation
are divided and consolidated into batches whose starting quantity = 1,000 blanks. Printing cycle
rate = 30 blanks/min. Between batches, a changeover of the printing plates is required, which
takes 20 minutes. In-process inventory is allowed to build up between machines 1 and 2, and
between machines 2 and 3, so that the machines can operate independently as much as possible.
Based on this data and information, determine the maximum possible output of this factory
during a 40-hour week, in completed blanks/week (completed blanks have been cut, indented,
and printed)? Assume steady state operation, not startup.

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