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Tutorial 2 - Solution

The document contains solutions to 8 questions about manufacturing systems and lean production. It defines key terms like processing, assembly, hard and soft product variety, just-in-time delivery, and continuous improvement. It also shows sample calculations for determining the number of production operations, required floorspace, and necessary workers for two factory planning scenarios.

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Ruby Lim
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65 views

Tutorial 2 - Solution

The document contains solutions to 8 questions about manufacturing systems and lean production. It defines key terms like processing, assembly, hard and soft product variety, just-in-time delivery, and continuous improvement. It also shows sample calculations for determining the number of production operations, required floorspace, and necessary workers for two factory planning scenarios.

Uploaded by

Ruby Lim
Copyright
© Attribution Non-Commercial (BY-NC)
Available Formats
Download as PDF, TXT or read online on Scribd
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BEKC 4883

ADVANCE MANUFACTURING SYSTEM (2010/2011)

NAME : ANUAR BIN MOHAMED KASSIM COURSE : 4BEKM

TUTORIAL 2 (SCHEME)

1.

What is manufacturing?
Answer: Two definitions are given in the text, one technological and the other economic. The technological definition is the following: Manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products; manufacturing also includes the joining of multiple parts to make assembled products. The economic definition is the following: Manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations.

2.

What is the difference between a processing operation and an assembly operation?


Answer: A processing operation transforms a work material from one state of completion to a more advanced state that is closer to the final desired part or product. It adds value by changing the geometry, properties, or appearance of the starting material. An assembly operation joins two or more components to create a new entity, called an assembly, subassembly, or some other term that refers to the joining process.

3.

What is the difference between hard product variety and soft product variety?
Answer: Hard product variety is when the products differ substantially. In an assembled product, hard variety is characterized by a low proportion of common parts among the products; in many cases, there are no common parts. Soft product variety is when there are only small differences between products. There is a high proportion of common parts among assembled products whose variety is soft.

4.

What is lean production?


Answer: The definition given in the text is the following: Lean production means operating the factory with the minimum possible resources and yet maximizing the amount of work that is accomplished with these resources. Lean production also implies completing the products in the minimum possible time and achieving a very high level of quality, so that the customer is completely satisfied. In short, lean production means doing more with less, and doing it better.

5.

In lean production, what is just-in-time delivery of parts?


Answer: As defined in the text, just-in-time delivery of parts refers to the manner in which parts are moved through the production system when a sequence of manufacturing operations is required to make them. In the ideal just-in-time system, each part is delivered to the downstream workstation immediately before that part is needed at the station.

6.

In lean production, what does continuous improvement mean, and how is it usually accomplished?
Answer: Continuous improvement involves an unending search for ways to make improvements in products and manufacturing operations. It is usually accomplished by worker teams who cooperate to develop solutions to production and quality problems.

7.

The ABC Company is planning a new product line and will build a new plant to manufacture the parts for a new product line. The product line will include 50 different models. Annual production of each model is expected to be 1000 units. Each product will be assembled of 400 components. All processing of parts will be accomplished in one factory. There are an average of 6 processing steps required to produce each component, and each processing step takes 1.0 minute (includes an allowance for setup time and part handling). All processing operations are performed at workstations, each of which includes a production machine and a human worker. If each workstation requires a floor space of 250 ft2, and the factory operates one shift (2000 hr/yr), determine (a) how many production operations, (b) how much floorspace, and (c) how many workers will be required in the plant.

Solution: This problem neglects the effect of assembly time. (a) nof = PQnpno = 50(1000)(400)(6) = 120,000,000 operations in the factory per year. (c) Total operation time = (120 x 106 ops)(1min./(60 min./hr)) = 2,000,000 hr/yr. At 2000 hours/yr per worker, w =
2,000,000hr / yr = 1000 workers. 2000hr / wor ker

(b) Number of workstations n = w = 1000. Total floorspace = (1000 stations)(250 ft2/station) = 250,000 ft2

8.

The XYZ Company is planning to introduce a new product line and will build a new factory to produce the parts and assembly the final products for the product line. The new product line will include 100 different models. Annual production of each model is expected to be 1000 units. Each product will be assembled of 600 components. All processing of parts and assembly of products will be accomplished in one factory. There are an average of 10 processing steps required to produce each component, and each processing step takes 30 sec. (includes an allowance for setup time and part handling). Each final unit of product takes 3.0 hours to assemble. All processing operations are performed at work cells that each includes a production machine and a human worker. Products are assembled on single workstations consisting of two workers each. If each work cell and each workstation require 200 ft2, and the factory operates one shift (2000 hr/yr), determine: (a) how many production operations, (b) how much floorspace, and (c) how many workers will be required in the plant.

Solution: (a) Qf = PQ = 100(1000) = 100,000 products/yr Number of final assembly operations = 100,000 asby ops/yr Number of processing operations nof = PQnpno = 100(1000)(600)(10) = 600,000,000 proc ops/yr (c) Total processing operation time = (600 x 106 ops)(0.5 min./(60 min./hr)) = 5,000,000 hr/yr. Total assembly operation time = (100 x 103 asby ops)(3 hr/product) = 300,000 hr/yr Total processing and assembly time = 5,300,000 hr/yr

At 2000 hours/yr per worker, w =

5,300,000hr / yr = 2650 workers. 2000hr / wor ker

(b) With 1 worker per workstation for processing operations, n = w = 2500 = 2500 workstations. With 2 workers per stations for assembly, n = w/2 = 150/2 = 75 workstations. Total floor space A = (2575 stations)(200 ft2/station) = 515,000 ft2

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