Chapter 3, Problem 1P Problem (A) A batch of parts is produced on a semiautomated production machine. Baich size is 200 Units. Setup requires 55 min. A worker loads and unloads the machine each cycle, which takes 0.44 min, Machine processing time is 2.86 min/cycle, and tool handling time is negligible. One part is produced each cycle. Determine (a) average cycle time, (b) time to complete the batch, and (c) average production rate. Step-by-step solution Step1 Find the Average cycle time. min Therefore, average cycle time is [3.3 min] Step 2 Determine the time to complete the batch. T, = set up time + process time-+ non operation time ) 200%0.44min x \ 60 min ) 60 min = 11,916 =11.92 hr =| 33min as 200x2.86min x: ul 60 ‘Thererore, time to complete the batch is [[79 hr] Step Determine the average production rate. Batch size Substitute 11.92hr for 7, a 11.92 200 = 16.78 peshr R, ‘Therefore, average production rate is [16.78 pelhs|(Chapter 3, Problem 2P Probiem Ina bten macrning operation, stu nes 1.8 nan tach Seis 80 UNS. The Ce ‘me conse ct gerthanang tre ot 90 92 ana proceeig te ot #87 min. Gne pat proucoa each cyte, Tel cuanges rust ve partoraed every 10 pars arn kes 20 rin, Doterne fa) average yc be, (} me to complet he BEN, aa) average promton te sep ter tae te cyte te ysgol elton: heleTan 0) ere. the actual processing tres 7. fe hang tes 7, an the fol handing ne T. ‘abate te too change urea ots 1,=2minfor 10 prs ‘ene pats proaice each eye Theetore clea he oo change ine pe pat ‘in Tope 02min ‘Subsite | min CT, 306 OFT 24 02min FT, equa (1 in 21 31min 0 min O2min To Latin 304 02min 201 winx 6.0545 “Torte, he average eyo Cetatate mene compete me batch ToT sOr ote ne nate processing ume © 7, ha Setup te 7, shane nan quant Subst [she © T, 003 hr FT, a8 $0 units Or 0 Ter, 407, =1Semn.o04s 426 pe “norte, no be to compte he BatEN eps ‘ata te average production tne Subatute 0.0825hr)p fT, tl * ppsias 1875 phe “hereto, he average production aesChapter 3, Problem 6P (A) A mass-production plant has six machines and currently operates one &-hr shift per day. 5 days per week, 50 weeks per year. The six machines produce the same part each at a rate of 12 pc/hr. (a) Determine the annual production capacity of this plant. (b) Ifthe plant were to operate three 8-hr shifts per day, 7 days per week, 52 weeks per year, determine the annual percentage increase in plant capacity? step 1 Determine the annual production capactty of the plant. Obtain the number of hours of plant operation from the “Table 9.1 for the period of Shrishifl, Sday/week, SOweeks/year”, in the text book Substitute, 2000hrfor plant operation time Plant capacity = number of machines x operation hours x Production rate 200012 =144000 peiyear Therefore, annual production capacity of the plant is [144000 pe/year| Step 2 Determine the annual percentage increase in production capacity of ine plant. Determine the annual production capacity of the plant when plant operates ‘Three Shi/shift, 7day/week, 52weeks/year Obtain the number of hours of plant operation from the “Table 3.1 for the period of Three Shr/shift, 7day/week, S2weeks/year", in the text book, Substitute, §73¢hrfor plant operation time. number of machines x operation hours x Production rate 873612 =628992 pelyear Plant capacity 628992 -144000 Percentage increase in annual production capacit «100 Therefore, annual percentage increase in production capacity of the plant is [336.8%Chapter 3, Problem 8P Problem ‘job shop has four machines and operates 40 hwek During the most recent cok, Imacnine 1 processed part for 25 nr ata production rate of 10 pont. an par for 12 nr ata rae of7 por Machine 2 processed part C for 37 hr at rate of pf, anc was ile 2c Machine 2 processed part D fr 15 hv ata rate of 20 pot. ana part € fr 25 nv at 2 ‘alo of 15 per. Machine 4 processed part F for 13 hr at arate of 9 pot, part Gfor 12 {ta rate 018 pon, and was lle the rest ote week. Determine (a) WeekY production ‘output ortne shop and (0) average uttzation of equipment Step-by-step solution step 40) Determine tne weeyprocucton output ot tne shop. CCaleulte tne racton of te curing tne period that machine processing part For Machine? For Macrine2 a Ze For Machines fe= 22-0925 Fraction ofl tne on machine? s 07s Fracton of ae tne on mactines 378 CCacutste the average houry production output of the shop, Ry Bag, = (0628.10) + (03%7) (092514) (0.375420) + (0.628%15) +(0325%9}+(03%18) = 46 51860 pore Determine tne weey procucton output ott shop. Boge = MORAG = 1860 pesweck “Therefore, week production output ofthe shop i [86O pales] Step 20/2 Ccaculste me utizaton at tne equipment, y x (0625-103 0928 0375-0625 +028 +03) ~ (062s oo 09as+03754 06250325003) = 0.8687 =865% “Therefor, uzaton ofthe ecupmentChapter 3, Problem 9P A batch production plant works 40 hr/wk and has three machines. In a typical week, five batches of parts are processed through these machines. Production rates (pcihr), batch limes, and operation sequences for the parts are given in the table below for one week. (a) Determine the weekly production rate for the shop. (b) Is this weekly production rate equal to the plant capacity? If not, determine what the output would be if all three machines could be operated up 10 40 hr/wk, given the constraint that no reductions in weekly production rates are allowed for any part. Use of a spreadsheet calculator is recommended for this problem, Machine 1 | Machine 2 | Machine 3 Part | Rpi| Toi (nr)| Rp2| Tb2 (nr)| Res | 703 (nr) A|10| 18 |15] 10 |1875) 8 B lis] 14 10 | 21 c 8} 21 pd |20| 5 |as| 4 E 16| 5 10 8 Ask an expertChapter 3, Problem 107 Problem ‘There are 10 machines inthe autora lathe section af certain machine shop. The sup ‘ime on an automatic athe averages 5 hr Average bac Sze or parts processed through tne section 100. Average operon tme = 0 min Under shop rues, an operator can O& assigned foun one or two machines, According ere ae Te operators inte section for ‘he 10 lathes. n-adation tote late operators, here are to Setup workers who perorm only machine setups. These elin workers are busy the fl shi The eecon rns ane he shit per day. 5 cays per week Scrap losses are negigibe and avaiablty = 100%. The rosucton conto ranger clams thatthe capac ofthe secon shoul be 2,000 parts Derweek However, tne actual ouput averages oly 1.60 uns per week Whats he problem? Recommend a soliton Step-by-step solution step 40! cau tne numberof worang nours per Week ‘Number of hours/week =SdayiveckShriday -40hrweok (cate ne precucton time 1,407, @ Here, 1, eset uptime, @ Ise quanty of pans, 7, te cyte te for operavon 1, step 201 Calculate he procucton rate , 1 7, 1 02 Spethe ‘eter ie production capacty ef ne ekant Plant capacity = numberof machines operation hours Production rate 0 40%5 ~2000peiwesk ‘Theretore, production capacty oF the plant [2000 pefwesk] step Suthe ace ouptis6tounisinesk (2setup men) (Aone) ‘Ghrscp) Socesvesk At Optic Tal pveck = 16100 ~1600pemeck The podem thats wore reoresen abt nck T sae he probe en nore setup ocr ere egured [Number of batches setup‘Chapter 2, Problem 19P (Acountecrtpa stag anna shampoos ft te omar ane |so|a5fea|sa]enfos| eps stp wecrenn rain asetopin ne as son ase tine Meron(t.s00-1.) Maron(tvenen) tied yan SET tamara opetne ose hse eue um edn pn‘Chapter 3, Problem 12° Supe par ne eves oem sae ver gens On a HesHICN acts Tastee eteen soi 6 Tame que setup eee 2s ne prenus rede Oem 2 ma wocng bed ef pa cng Ine tne (easton a een 3 (eae peasson ee ene -Reaann ie 2} own oust pie 10000 pets afer no sp hasbeen ‘omatee? Step-by-step slton » ue a operon omeat ie ened aon meus 7, wean SubD 62 FM. 28 180% 7,8, ween uns seen arnt) ine mn srt 8)a9 ‘Tree, euresmartatrg acne re panconeg ete Wes » ‘Te mera paste ere peuten Wels BT] wxoue san 36 » ne cqutonore tn pase 1.000 pts ine en «2890 ne Bt ‘Tete, ented one kn roost afer ompeOn sesChapter 3, Problem 13P ‘A batch production plant processes an average of 35 batches of parts per week. Five of those part styles have been selected as a sample for analysis to assess the production performance of the plant. The five parts are considered to be representative of the population of parts processed by the plant. Any machine in the plant can be set up for any type of batch processed in the plant. Batch quantities, numbers of operations in the processing sequence, setup times, and cycle times for the parts are listed in the table below. The average nonoperation time per baich per operation is 11.5 hr. The plant operates 40 hriwk. Use this sample to determine the following measures of plant performance: (a) manufacturing lead time for an average part, (b) plant capacity if all machines could be operated at 100% utilization, and (c) work-in-process (number of parts in-process). Use of a spreadsheet calculator is recommended for this problem. Part j| Qj | naj] Tsu (hr) | Tey (min) | Tho (hr) A |1o0} 6} 50 93) 11.5 B |240] 3] 38 84) 11.5 c | 5] 4] 40 120) 11.5 p |2s0] 8] 61 or) 1.9 e |140] 7] 35 32) 11.5 Ask an expertChapter 3, Protiem 160 wron(toat ot.) Meron(ns0r-t.) 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