MENG 4444

Assignment 2 (10 points)- Spring 2017

2.24 A worker is currently responsible for tending two machines in a certain production cell. The service
time per machine is 0.35 min and the time to walk between machines is 0.15 min. The machine
automatic cycle time is 1.90 min. If the worker's hourly rate is $12/hr and the hourly rate for each
machine is $18/hr, determine (a) the current hourly rate for the cell, and (b) the current cost per unit
of product, given that two units are produced by each machine during each machine cycle. (c) What is
the percentage of idle time of the worker? (d) What is the optimum number of machines that should
be used in the cell, if minimum cost per unit of product is the decision criterion?

2.25 In a worker-machine cell, the appropriate number of production machines to assign to the worker is to
be determined. Let n = the number of machines. Each production machine is identical and has an
automatic processing time Tm = 4.0 min to produce one piece. Servicing time Ts = 12 sec for each
machine. The full cycle time for each machine in the cell is Tc = Ts + Tm. The walk time (repositioning
time) for the worker is given by Tr = 5 + 3n, where Tr is in seconds. Tr increases with n because the
distance between machines increases with more machines. (a) Determine the maximum number of
machines in the cell if no machine idle time is allowed. For your answer, compute (b) the cycle time, (c)
the worker idle time expressed as a percentage of the cycle time, and (d) the production rate of the
machine cluster.

3.3 A factory produces cardboard boxes. The production sequence consists of three operations: (1) cutting,
(2) indenting, and (3) printing. There are three automated machines in the factory, one for each
operation. The machines are 100% reliable and the scrap rate in each operation is zero. In the cutting
operation, large rolls of cardboard are fed into the cutting machine, which cuts the cardboard into
blanks. Each large roll contains enough material for 4000 blanks. Production time = 0.03 min/blank
during a production run, but it takes 25 min to change rolls and cutting dies between runs. In the
indenting operation, indentation lines are pressed into the printed blanks that allow the blanks to later
be bent into boxes. Indenting is performed at an average time of 2.5 sec. per blank. Batches from the
previous cutting operation are subdivided into two smaller batches with different indenting lines, so that
starting batch size in indenting = 2000 blanks. Time to change dies between batches on the indenting
machine = 30 min. In printing, the blanks are printed with labels for a particular customer. Starting batch
size in printing = 2000 blanks (these are the same batches as in indenting). Production rate = 30
blanks/min. Between batches, changeover of the printing plates is required, which takes 40 min. What is
the maximum possible output of this factory during a 40 hour week, in printed and indented
blanks/week. Assumptions: (i) steady state operation and (ii) there is work-in-process between
operations 1 and 2 and between 2 and 3, so that blocking and starving of operations is negligible. (Not
part of the assignment)

3.4 Solve the previous problem except that the reliability of the cutting machine is 80% (availability or
uptime proportion = 80%), the reliability of the indenting machine = 95%, and the reliability of the
printing machine = 85%. These reliability factors apply only when the machines are producing, not during
setup or changeovers.
3.7 There are 20 automatic turning machines in the lathe department. Batches of parts are machined in
the department. Each batch consists of setup and run. Batch size = 100 parts. The standard time to set
up a machine for each batch is 5.0 hours. Four setup workers perform the setups. They each work 40
hours per week. Once a machine is set up, it runs automatically, with no worker attention until the
batch is completed. Cycle time to machine each part = 9.0 min; thus, it takes 15 hours of run time to
produce a batch. Assume all machines are perfectly reliable. (a) What is the production output of the
lathe department in 40 hours of operation per week? (b) How many machines are idle (not in use or
being set up between production runs) on average at any moment?

3.20 Three sequential operations are required for a certain automotive component. Operation 1 has a
defect rate = 4%. Operation 2 has a defect rate = 5%. Operation 3 has a defect rate = 10%. Operations 2
and 3 can be performed on units that are already defective. If 25,000 starting parts are processed
through the sequence, (a) how many units are expected to be defect-free, (b) how many units are
expected to have exactly one defect, and (c) how many units are expected to have all three defects?

3.23 A factory is dedicated to the production of one product. One unit of raw material is required for each
unit of product. Two processes are required to produce the product, process 1, which feeds into
process 2. A total of eight identical machines are available in the plant that can be set up to perform
either process. Once set up, each machine will be dedicated to the performance of that process. For
each machine set up for process 1, production rate = 10 units per hour. For each machine set up for
process 2, production rate = 6 units per hour. Process 1 produces only good units, but process 2 has a
scrap rate of 20%. A work-in-process buffer is allowed between the two processes so that process 2
will not be starved for work. The factory operates 40 hours per week. (a) In order to maximize factory
production, how many machines should be set up for process 1, and how many machines should be set
up for process 2? (b) What is the factory’s maximum possible weekly production rate of good product
units? (c) How many starting units of raw material are needed each week to attain this production
rate?

3.1 Four parts (A, B, C, and D) are processed through a sequence of four operations (1, 2, 3, and 4). Not all
parts are processed in all operations. Part A, which has weekly quantities of 70 units, is processed
through operations 1, 2, and 3 in that order. Part B, which has weekly quantities of 90 units, is
processed through operations 2, 4, and 1 in that order. Part C, which has weekly quantities of 65 units,
is processed through operations 3, 2, and 4 in that order. Finally, part D, which has weekly quantities
of 100 units, is processed through operations 2, 1, and 4 in that order. (a) Draw the network diagram
and (b) prepare the From-To table for this work system. . (Not part of the assignment)

3.26 For Problem 3.1, (a) use the Hollier algorithm to determine the most logical in-line sequence of
workstations in the work system, and (b) compute the percentage of in-sequence moves, backflow
moves, and by-passing moves for the sequence

Guideline:
 Assignment may be solved individually or in groups of 2 students.
 Due electronically by 9 March 2017. Please send as a pdf or word document attached to an
email to Eng. Moataz with the subject "MENG 4444: Assignment #2".
 Your document may include captured images of legible handwriting or hand drawings.
 Should follow the guidelines given on the teaching policies document.
 No discussion of this assignment after my office hours on the 8th of March.