K Chiteka Tutorials

1. Outline, giving relevant examples, the characteristics of each of the following manufacturing generics; [explain in terms of; volume, machinery and investment, manpower, scheduling & routing, products] i) Project [5] ii) Jobbing [5] iii) Batch [5] iv) Line [5] v) Continuous [5]

2. Explain the business implications of the process choice ASPECTS Product type Product range Order size New prod. Intro. Process technology Process flexibility Volumes Investment R/Material inventory F/ Goods Inventory PROJECT JOBBING BATCH LINE CONTINUOUS

[15]

3. (a) Giving examples, briefly explain the Hybrid process (b) Describe the following batch related hybrids; i. ii. NC Machining centre

[5]

[5] [5]
Page 1

Department of Industrial and Manufacturing Engineering

iii. iv. v.

FMS GT Transfer lines

[5] [5] [5]

4. a) Outline the objectives of a good plant layout 1. Briefly explain the following layouts; i. Process layout ii. Product layout iii. Cellular layout iv. Fixed position layout v. Hybrid layout

[5] [5] [5] [5] [5] [5]

5.

The following data relates to an automotive repair shop. You are required to come up with an optimal plant layout that minimizes operational costs. Also fit-in the departments in a flow space of 5550m2.

The departments are as follows; A B C D E F G Receiving bay Workshop supervisor Materials store room Panel beating bay Spray booth Quality control Dispatch

Space Allocation Area Department (m2) A 1000

Department of Industrial and Manufacturing Engineering Page 2

B C D E F G

50 900 2000 400 200 1000

FROM-TO CHART A A B C D E F G B 100 C 500 D 50 400 E 50 900 1000 1000 1000 F G

[20]

6. It has been ascertained that the ideal cycle time, Tc of a particular product is 1.1 minutes. Breakdowns occur at a frequency, F = 0.13 per cycle. The average downtime per line stop is 4.3 minutes (Td =4.3 minutes). The scrape rate is 4.31%. The initial cost of the component is $.93 and it costs $53 per hour to operate the transfer line. Cutting tools cost 13c per work-part. a) Find; i. The production rate [1] ii. The number of hours required to meet a demand of 2351 units per week [1] iii. Line efficiency [1] iv. Cost per unit produced [2]

b) A nine-station transfer line has .03 as the probability that a workstation will breakdown. Determine; i. The frequency of line stops per cycle using the upper bound & lower bound approach. [2] ii. The production rate [3]
Department of Industrial and Manufacturing Engineering Page 3

7. Below is a from-to chart showing the relative movemwnts between departments. The initial arrangement of departments is 1-2-3. To dept 1 1 2 3

from dept

2 10

3 5 20

Use the pair-wise exchange method to determine the optimal solution.

[10]

8. Table Q6.1 below provides the data relating to work elements, individual cycle times, and precedence constraints.

Work element 1 2 3 4 5 6 7 8 9 10

Tej 0.15 0.21 0.72 0.13 0.3 0.11 0.63 0.51 0.33 0.31

Preceded by 1 2 3 3 3,4 5,6 5 7,8 9

Assuming a cycle time of .89 minutes, determine the minimum number of workstations required. i. ii. Using the Largest candidate rule Using the Ranked Positional weight method

Department of Industrial and Manufacturing Engineering Page 4