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Assignment 2

The document outlines an assignment for a Facilities Planning and Material Handling course, focusing on schedule design, notations, and equations related to production processes. It includes tutorial and practice problems that require calculations for production requirements, machine needs, and scrap rates for various operations. Final answers for the problems are also provided, along with a micro-project task that involves demand justification and machine calculations.

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31 views4 pages

Assignment 2

The document outlines an assignment for a Facilities Planning and Material Handling course, focusing on schedule design, notations, and equations related to production processes. It includes tutorial and practice problems that require calculations for production requirements, machine needs, and scrap rates for various operations. Final answers for the problems are also provided, along with a micro-project task that involves demand justification and machine calculations.

Uploaded by

doaa atef
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Faculty of Engineering

Production Engineering Department


PED 351 – Facilities Planning and Material Handling
Fall 2022

Assignment 2: Schedule Design


Notations and Equations
Ok = Ik – dk Ik
Ik = Ok ⁄(1 − dk )
O k : Desired output of non-defective products from operation k
Ik: Production requirement (input) to operation k
d k: Defective items (scrap) percentage on the 𝑘 𝑡ℎoperation

I1 = On ⁄[(1 − d1 )(1 − d2 ) … (1 − dn )]
I1: Expected number of units (input) to start production on a part requiring n operations.
F = Total Time⁄Time Available = SQ / EHR
F: Required number of machines per shift or per unit time
S: Standard time per unit produced "machining time, forming time" [min]
Q: Number of units to be produced per shift or per unit time "not demand" [units/shift]
E: Actual performance or worker efficiency (as % of standard time) [%]
H: Amount of time available per machine [min]
R: Machine reliability (as % “uptime”) [%]

Tutorial Problems
1. Given the following figure, operation 4 represents a rework operation on parts that fail
inspection upon completion of operation 2. How many units must the process start with in
order to meet the required output of 5000 units?

2. A machined part has a machinery time of 2.5 minutes per part on a milling machine. During
an 8-hr shift 250 units are to be produced and the milling machine will be operational 80%

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of the time. During the time the machine is operational, parts are produced at a rate equal
to 95% of the standard rate. How many milling machines are required?

3. Part X requires two operations (A & B) on a milling machine. Find the number of machines
required to produce 3,000 parts per week. Assume the company will be operating 5 days
per week, 18 hours per day. The following information is known:

Operation Standard Time Efficiency Reliability Scrap


A 3 min 95% 95% 2%
B 5 min 95% 90% 5%
Note: The milling machine requires tool changes and preventive maintenance after every
lot of 500 parts. These changes require 30 minutes.

Practice Problems
4. A computer recycler sells computer enclosures to a computer remanufacturer. To meet
monthly expected demand, the remanufacturer needs 2,000 enclosures. The recycler utilizes
a four-step disassembly process with scrap rates given as follows: d 1 =0.08, d 2 =0.05,
d 3 =0.05, and d 4 =0.03. How many computers must the recycler receive each month in order
to meet the remanufacturer’s demand?
5. Consider a simple three-step manufacturing process as illustrated in the following figure.
Assuming that demand is 1,000 units, what is the required input to meet demand? You’ll
note that the required input is the same if the scrap rates are reversed for processes 1 and 3.
Assume that the scrap cost is $5 at process 1, $10 at process 2, and $15 at process 3. The
defective rates are 3%, 5%, and 7%, respectively. Compute the total scrap cost for the given
system and the system where the scrap rates are reversed. Which system would be
preferred?

6. Consider the previous problem where, in this case, each process is capable of rework. Given
the information in the following table, what is the input required to satisfy a demand of
1,000 units?

Process Defect Rate Rework Defective Rate


1 3% 40%
2 5% 25%
3 7% 20%
Suppose that scrap costs are negligible, and rework costs are $2, $3, and $4, respectively.
Calculate the rework cost for producing the 1,000 units. What happens to the rework cost if
the scrap rates on processes 1 and 3 are reversed? Does this result agree with that of the
previous problem?

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7. During one 8-hr shift, 750 non-defective parts are desired from a fabrication operation. The
standard time for the operation is 15 min. Because the machine operators are unskilled, the
actual time it takes to perform the operation is 20 min and, on the average, one-fifth of the
parts that begin fabrication are scrapped. Assuming that each of the machines used for this
operation will not be available for 1 hr each shift, determine the number of machines
required.
8. Given the following, what are the machine fractions for machines A, B, and C to produce
parts X and Y?
Machine A Machine B Machine C
Part X standard time 0.15 hr 0.25 hr 0.10 hr
Part Y standard time 0.10 hr 0.10 hr 0.15 hr
Part X scrap estimate 5% 4% 3%
Part Y scrap estimate 5% 4% 3%
Historical efficiency 85% 90% 95%
Reliability factor 95% 90% 85%
Equipment availability 1,600 hr/yr 1,600 hr/yr 1,600 hr/yr
Part X routing is machine A, then B, and then C; 100,000 parts are to be produced per year.
Part Y routing is machine B, then A, and then C; 200,000 parts are to be produced per year.
Setup times for parts X and Y are 20 min and 40 min, respectively.
9. Part A is produced on machine 1 and then machine 2. One unit of Part A is assembled with
three units of Part B, which is produced on machine 3, in assembly station 4. Machine 1 has
a scrap factor of 20%, and machine 2 has a scrap factor of 10%. The assembly process has
a scrap factor of 15%. Another part, Part C, is produced on machine 5 and has a scrap
estimate of 25%. Part C and the subassembly consisting of Part A and Part B are assembled
at assembly station 6 into the completed product. Each day, 15,000 units of the completed
product are required to meet demand. Assuming that machine 3 and assembly station 6 have
scrap factors of 30% each, what are the requirements for Parts A, B, and C in order to meet
the daily demand for the completed product?
10. Suppose that in the previous problem, each process was able to reduce its scrap estimate by
5%. What would the percent change in the requirement for each input be? What significance
can this have on the process designer’s decision-making process?
11. Suppose that a final assembly is produced by assembling two components. The first
component, component A, is produced in-house and proceeds through three process steps,
blanking, forging, and machining, with scrap estimates of 10%, 15%, and 25%,
respectively. For every three units of component A produced, two are used in the final
assembly, and one is set aside to meet spare parts requirements. The second component,
component B, used exclusively in the final assembly, is purchased from an outside vendor
and is inspected upon arrival; 2% fail inspection. One unit of the purchased component is
required for each final assembly. The final assembly process produces 5% scrap. The
demand for the spare parts of component A and the final assembly are 1000 and 5000 units,
respectively. How many units of input are required to produce component A, and how many
units must the company buy of component B?

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Final Answers
1. 5854 units.
2. 2 machines.
3. 6 machines.
4. 2484 units.
5. $1,865 and $1,415.
6. $499 and $419.
7. 45 machines.
8. 30, 39, and 32 machines.
9. 35,014, 108,043.22, and 28,571 units.
10. 27,520, 88,888, and 25,000 units.
11. 20,089 and 5,371 units.

Micro-Project Task (2)


1. State the annual demand of your product. Justify your assumption.
2. Calculate the production requirement for each operation to satisfy your demand (show all
calculations).
3. For each component, calculate machine fraction for each operation using the following table
(show all calculations and state units of each parameter):
Operation Name Machine Name S Q E H R Setup Time F
4. Calculate the number of required machines for each type.
5. Determine the total number of operators needed in the production area and the number of
operators for each machine type.

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