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Process Planning

1. The document provides 9 sample problems for calculating machine requirements and determining the most economical machine option for manufacturing components. It includes data on set-up times, operating cycle times, lot sizes, production quantities, machine specifications, and labor and machine costs. 2. The problems require calculating the number of machines needed based on component production needs, determining the most economical machine to use based on set-up and operating costs, and identifying the machine that can satisfy required production capacity levels. 3. Solutions are provided for each sample problem to demonstrate how to analyze the data and select the best machine or calculate machine requirements.

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sujit kc
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217 views2 pages

Process Planning

1. The document provides 9 sample problems for calculating machine requirements and determining the most economical machine option for manufacturing components. It includes data on set-up times, operating cycle times, lot sizes, production quantities, machine specifications, and labor and machine costs. 2. The problems require calculating the number of machines needed based on component production needs, determining the most economical machine to use based on set-up and operating costs, and identifying the machine that can satisfy required production capacity levels. 3. Solutions are provided for each sample problem to demonstrate how to analyze the data and select the best machine or calculate machine requirements.

Uploaded by

sujit kc
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOC, PDF, TXT or read online on Scribd
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PROCESS PLANNING

1. Calculate the number of machines required to manufacture three components from the
following data:
Components A B C
1. Setting time per lot 25 min 55 min 45 min
2. Operating Cycle time/piece 1.75 min 3 min 2.1 min
3. Lot size 350 550 575
4. Production per month 2450 4400 2875
The plant is working for 8 hrs per day in one shift.
Solution: 3
2. Determine the economical machine for a particular component using the following
data.
Capstan Lathe Auto Lathe
1. Set up time 1 hr 6 hrs
2. Operating time 10 min 2 min
3. Set up labor cost 7 Rs./hr 7 Rs. /hr
4. Operating labor cost 5 Rs./hr 2 Rs. /hr
5. Tooling cost Nil 200 Rs.
6. Machine overheads 15 Rs. /hr 28 Rs./hr
7. Lot size 1500 nos 1500 nos
Solution: Auto lathe more economical.
3. Three different products are to be manufactured on the following machines. Calculate
the number of machines required for processing these products if the plant works 45
hours per week.
Equipment Time Product I Product II Product III
1. Center lathe Set up 30 min 55 min 40 min
Operating 2 min 2.5 min 1.5 min
2. Milling M/C Set up 45 min 30 min -
Operating 8 min 4 min -
3. Cylindrical grinding M/C Set up 50 min - 54 min
Operating 10 min - 7.2 min
Lot size 350 400 600
Quantity required/month 1750 4000 3000
Solution: Center lathe: 2; Milling M/C: 3; Cylindrical Grinders: 4
4. Find out the break – even quantity, if the estimated time and cost for the two
alternative methods is as given below.
Method Set up time Machining time/piece Set up cost/hr Machining cost/hr
Turret lathe 4.5 hrs 4 min Rs. 35/- Rs. 15/-
Center lathe 30 min 35 min Rs. 15/- Rs. 25/-
Solution: 11 piece
5. Following data refer to three different machines A, B and C. The output is expected to
be 9000 products per month. Factory works for 48 hours per week. Find out the machine
which will satisfy the required capacity.
Particulars Machines
A B C
Machine set up time in min 9 4 6
Machine operation time in min/piece 1.2 2.0 1.5
Lot size 450 300 360
Solution: Machine A
6. Calculate the number of automata required to manufacture three components from the
following data:
Particulars Components
A B C
1. Setting time per lot 27 min 57 min 40 min
2. Operating Cycle time/piece 1.8 min 3 min 2 min
3. Lot size 350 500 550
4. Production per month 2000 4500 3000
The plant is working for 45 hours per week.
Solution: 3
7. Following data refer to three different machines X, Y and Z. Calculate acceptable
production of each machine per day. Factory works for one shift of 8 hours per day. The
workers are allowed 40 minutes of time allowance during the shift.
Particulars Machines
X Y Z
Machine set up time in min 5 10 15
Machine operation time in min/piece 7.6 6.9 5.1
Lot size 50 150 300
No. of allowable scrap units per lot 5 11 25
Solution: Machine A
8. Determine the economical machine for a particular component using the following
data.
Capstan Lathe Auto Lathe
1. Set up time 0.5 hr 6 hrs
2. Operating time 35 min 2 min
3. Set up labor cost 7 Rs./hr 7 Rs. /hr
4. Operating labor cost 6 Rs./hr 2 Rs. /hr
5. Tooling cost Nil 200 Rs.
6. Machine overheads 10 Rs. /hr 28 Rs./hr
7. Lot size 1500 nos 1500 nos
Solution: Auto lathe more economical.
9. What would be the minimum production quantity to justify the milling machine, given
in the following information.
Particulars Shaping M/C Milling M/C
1. Set up time 30 min 60 min
2. Operation time 12 min 6 min
3. Labor rate 5 Rs./hr 5 Rs./hr
4. Machine rate 10 Rs./hr 15 Rs./hr
5. Tooling cost 100 Rs. 400 Rs.

Solution: 313 per month *************

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