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    Mfdmia2 Test I 2022

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    Mfdmia2 Test I 2022

    Uploaded by

    taku8401
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    Mfdmia2 Test i 2022

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    © © All Rights Reserved

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    10 views3 pages

    Mfdmia2 Test I 2022

    Uploaded by

    taku8401

    Copyright:

    © All Rights Reserved
    Download as DOC, PDF, TXT or read online from Scribd
    Download as doc, pdf, or txt
    of 3

    DEPARTMENT OF INDUSTRIAL ENGINEERING TECHNOLOGY

    MANUFACTURING SYSTEMS DESIGN

    MFDMIA2

    TEST I
    TIME - 2hrs 01/04/2022

    Answer all questions

    QUESTION 1

    A CNC lathe machine is programmed to turn a tapered shaft. The cycle time is 22.0 min.
    Time to load and unload is 4.5 min.

    a) Loading and unloading is done manually on the machine. Determine the Cycle time
    and hourly production rate? (4)

    b) If the machine tool is fitted with an automatic pallet changer that interfaces with a
    parts storage unit whose capacity is 12 parts, and reposition time = 25 sec. Calculate
    cycle time and hourly production rate?

    (4)

    c) How long will it take a worker to perform the loading and unloading of the 12 parts?
    How long will the machine operate unattended between parts changes?

    (4)
    [12]

    QUESTION 2
    A new forging plant must supply parts to a retail outlet. The plant will operate 24
    hour/day, 5 days/week, and 50 weeks/year. The total output from the plant must be 900
    000 forgings in batches of 1200 parts per year. Anticipated Scrap rate is 2%. Each
    forging cell will consists of a furnace to heat the parts, a forging press and a trim press.
    Parts are placed in the furnace an hour prior to forging, they are then removed, forged and
    trimmed one at a time. The cycle time is 1.5 mins per part. Each time a new batch is
    started, the forging cell must be set up again, which consists of changing the forging and
    trimming dies for the next batch. This takes 3.5 hours on average. Each cell is considered
    to be 96% reliable during operation and 100% reliable during changeover.

    a) Determine the number of forging cells that would be required in the new plant

    (10)
    b) What is the proportion of time setup for each batch?

    (2)

    [12]

    QUESTION 3

    3.1 What is a manual assembly line? (2)

    3.2 What is the difference between blocking and starving? (4)

    3.3 A new product is to be assembled on a manual assembly line. The line is to be


    designed to produce 180 000 units/year. Work content time for the product is 42.5 min.
    The assembly line will operate will operate 48 weeks/year, 5 shifts/week, 8 hour/shift.
    Proportion Uptime is 97%. There will be one worker per station. Determine:

    a) Cycle Time, Tc. (3)

    b) Theoretical minimum number of workers on the line. (3)

    [12]

    QUESTION 4

    A machine operator is assigned two machines in a machine cell. The service time per
    machine is 0.30 min and the time to walk between machines is 0.15 min. the machine
    automatic cycle time is 2.0 min. if the worker’s hourly rate is R50/hr and the hourly rate
    for each machine is R20/hr. Calculate:
    a) The hourly operating cost for the cell

    (2)
    b) The unit production cost, assuming two units are produced by each machine
    during each machine cycle

    (6)
    c) What is the percentage idle time of the workers?

    (2)
    d) Determine the maximum number of machines that should be allocate in each
    machine cell, in order to achieve the lowest production cost

    (10)

    [20]

    Total [56]

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