ISE324 FUNDAMENTALS OF MODERN MANUFACTURING SYSTEMS

FINAL EXAM

05.06.2011

1. Given the part mix, process routings, and processing times for the four parts in the table below,
the FMS proposed to machine these parts will operate 20 hours per day, 250 days per year. The
operation frequency fijk = 1.0 for all operations. Determine
(a) how many servers at each station will be required to achieve an annual production rate of
75,000 parts per year, (10 points)
(b) the utilization of each workstation. (10 points)
(c) What is the maximum possible annual production rate of the system if the bottleneck station
were to operate at 100% utilization, (10 points)
(d) average utilization of the system U s , if the bottleneck station is operated at 100% utilization (5
points)

Part j

Part mix pj

Operation k

Description

Station i

Process time tijk

0.2

0.2

0.25

0.35

1
2
3
4
5
1
2
3
4
5
6
1
2
3
4
1
2
3
4

Load
H. Mill
V Mill
Drill
Unload
Load
Drill
H. Mill
V. Mill
Drill
Unload
Load
H. Mill
Drill
Unload
Load
V. Mill
Drill
Unload

1
2
3
4
1
1
4
2
3
4
1
1
2
4
1
1
3
4
1

4 min
15 min
14 min
13 min
3 min
4 min
12 min
16 min
11 min
17 min
3 min
4 min
10 min
9 min
3 min
4 min
18 min
8 min
3 min

Solution:(a)
H = (20 hr/day)(250 days/yr) = 5000 hr/yr
Rp =

75,000 pc / yr
= 15 pc/hr = 0.25 pc/min
(5000hr / yr )

WL1 = (4+3)(0.2)(1.0) + (4+3)(0.2)(1.0) + (4+3)(0.25)(1.0) + (4+3)(0.35)(1.0) = 7.0 min

WL2 = 15(0.2)(1.0) + 16(0.2)(1.0) + 10(0.25)(1.0) = 8.7 min
WL3 = 14(0.2)(1.0) + 11(0.2)(1.0) + 18(0.35)(1.0) = 11.3 min
WL4 = 13(0.2)(1.0) + (12+17)(0.2)(1.0) + 9(0.25)(1.0) + 8(0.35)(1.0) = 13.45 min

s1 = Minimum Integer (0.25(7.0) = 1.75) = 2 servers (load/unload workers)

s2 = Minimum Integer (0.25(8.7) = 2.175) = 3 servers (horizontal mills)
s3 = Minimum Integer (0.25(11.3) = 2.825) = 3 servers (vertical mills)
s4 = Minimum Integer (0.25(13.45) = 3.362) = 4 servers (drill presses)
(b) U1 = 1.75/2 = 0.875 = 87.5%
U2 = 2.175/3 = 0.725 = 72.5%
U3 = 2.825/3 = 0.942 = 94.2%
U4 = 3.362/4 = 0.841 = 84.1%
(c) Maximum utilization is at station 3. If station 3 were to operate at 100% utilization,
Rp* = 15/0.942= 15.923 pc/hr
Annual production = 15.923 (20) (250) = 79,615 pc/yr = 15.923 pc/hr = 0.265 pc/min
(d) U1 = (0.265) 7/2 = 0.9275 = 92.8%
U2 = (0.265) 8.7/3 = 0.76 = 76%
U3 = (0.265) 11.3/3 = 1.0 = 100%
U4 = (0.265) 13.45/4 = 0.89 = 89%
U s = (2*0.927+3*0.76+3*1.0+4*0.89)/12 = 0.891 = 89.1%

2. On an automated transfer line there are two stages with a storage buffer between them. Stage 1
consists of 8 stations and frequency of failure for each station is p=0.0125. Stage 2 has 10
stations and frequency of failure for each station is p=0.009 (total of 18 stations on the line). The
ideal cycle time of each stage is Tc = 1.0 minute. The average downtime per stop is Td = 8.0
minutes, and a constant downtime distribution should be assumed. Determine the required
capacity of the storage buffer (b) such that the improvement in line efficiency E compared to a
zero buffer capacity (Eo ) would be 80% of the improvement yielded by a buffer with infinite
capacity (E ). This means that Eb = Eo + 80% *( E - Eo ). Assume L= 0. (20 points)
Solution:
For b = 0,
F = 8(0.0125) + 10 (0.009)= 0.19
Tp = 1.0 + 0.19(8.0) = 1.0 + 1.52 = 2.52 min/pc.
Eo = 1.0/2.52 = 0.3968
For b = ,
F1 = 8(0.0125) = 0.10
Tp1 = 1.0 + 0.01(8.0) = 1.0 + 0.8 = 1.8 min/pc.
E1 = 1.0/1.8 = 0.5555

F2 = 10(0.009) = 0.09
Tp2 = 1.0 + 0.009(8.0) = 1.72 min/pc
E2 = 1.0/1.72= 0.5814

E = min {E1, E2} = E1 = 0.5555

E = 0.55555 - 0.3968 = 0.1587
80% of E = 0.80(0.1587) = 0.127
E = 0.3968 + 0.127 = 0.5238 = E at 80% improvement
Eb = Eo + D1 h(b) E2 = 0.5238

so D1 h(b) E2 = 0.127

D1 = 0.8/2.52 = 0.3175
0.127 = 0.3175 h(b) (0.5814)

h(b) =

0.127
= 0.69
(0.3175)(0.5814)

- If we assume F1 = F2
r=

F1
T

B
1
= 1.0, therefore h(b) =
+ L c

B 1
F2
Td ( B 1)( B 2)

L= 0.
B
0.69(B+1) = B
B 1
T
B = 2.23 b = B d = 2.23(8/1) = 17.84 = 18 = buffer capacity
Tc

h(b) = 0.69 =

Since F1 F2
r = 0.1/0.09 =1.1111

h(b) = r (1 r B) / (1 r B+1) = 0.69

(1 r B) = (1 r r B) 0.69/1.1111
r B = 1.23

if you solve this 0.38 = 0.31 r B

log 1.23 = B log 1.1111

B= log1.23/log1.1111= 1.94

T
B = 1.94 b = B d = 1.94(8)/1= 15.47 = 16 buffer capacity
Tc

3. The following table lists the weekly quantities and routings of ten parts that are being considered
for cellular manufacturing in a machine shop. Parts are identified by letters and machines are
identified numerically. For the data given,
(a) develop the part-machine incidence matrix, (5 points)
(b) apply the rank order clustering technique to the part-machine incidence matrix to identify
logical part families and machine groups. (10 points)

Part
A
B
C
D
E

Weekly quantity
150
20
75
10
112

Machine routing
327
61
65
651
3274

Solution: (a) See step 1. (b) See steps 1 through 4.

Part
F
G
H
I
J

Weekly quantity
60
15
100
140
15

Machine routing
51
3 2 4
3 2 4 7
247
561

Step 1
A B C D E F G H I
1
2 1
3 1
4
5
6
7 1

1
1
1
1

1
1

1
1

1
1
1

1
1
1

1
1

1
1
1

B C F

1
1
1
1
1

1
1

1
1
1

1
1
1

1
1
1

1
1

1
1

Step 2
A B C D E F G H I

Ran
k
5
1
2
7
6
4
3

1
1
1
1

Step 3
E H A G I D J
2
3
7
6
1
5
4

1
1

2
3
7
6
1
5
4
Ran
k

1
1
1

1
1
1
1
1

1
1
1

1
3

1
1

1
1
1

Part families and machine groups:

1
1
1
1

1
1 1 1
9 6 1 10 4 2 5 7

2 1
3 1
7 1
4 1
6
1
5
Ran 1
k

1
1

Step 4
E H A G I D J

Ran
k
1
2
3
5
6
7
4

1
1
1
1

1
1
1

1
1
1

B C

1
1
1

1
1
1
6

1
1
1
7

1
1
8

1
1
9

I = (E, H, A, G, I) and (2, 3, 7, 4)

II = (D, J, B, C, F) and (6, 1, 5)

4. For the above problem (question 3), assume that products A, E, G, H and I form a family to be
manufactured on machines (2,3,4, 7).
(a) Determine the most logical sequence of machines for this data using Table above. (10 points)
(b) Construct the network diagram for the data. (10 points)
(c) Compute the percentages of in-sequence moves, bypassing moves, and backtracking moves
in the solution. (5 points)
Solution: (a) Hollier method applied to first machine group (machines 2, 3, 4, 7):

2
2 3 377
7
4
To 377

Step 1
7
4
262

255

240
502

112
367

From
517
377
112
240

2
3
7
4

From
sums
517
377
112
240

Step 2
To
sums
377
0
502
367

From/To
ratio
1.37

0.22
0.65

Order
2
1
4
3

1
1
10

Sequence:

(b) Network diagram

262
377

377

255

240

390

112
140

127

(c) % in-sequence moves = (377 + 255 + 240)/1246 = 0.70 = 70%

% bypassing moves = 262/1246 = 0.21 = 21%
% backtracking moves = 112/1246 = 0.09 = 9%

5. In the operation of an automated production line with storage buffers, what does it mean if a
buffer is nearly always empty or nearly always full? (5 points)

Answer: In the operation of an automated production line with storage buffers, if any of the
buffers are nearly always empty or nearly always full, this indicates that the production rates of
the stages on either side of the buffer are out of balance and that the storage buffer is serving
little useful purpose.