Automation question bank

1) Define automation? Explain its types?

2) List reason for automation?
3) List any 5 arguments for & against automation?
4) Briefly explain levels of automation?
5) Define MLT, Rp, PC, U, A?
6) Define WIP? WIP ratio & TIP ratio?
7) A certain part is routed through six machines in a batch production plant. The setup & operation
times for each machine are given in the following table.

Machine Setup time in hour Operation time in minute

1 4 5.0
2 2 3.5
3 8 10.0
4 3 1.9
5 3 4.1
6 4 2.5
The batch size is 100 & the average nonoperational time per machine is 12 hours.

Determine a)MLT b) Rp for operation 3.

8) The average part produced in a certain batch manufacturing plant must be processed through
an average of 6 machines. There are 20 new batches of part launched each week. Other
pertinent data are as follows.
Average operation time = 6 min.
Average setup time = 5 hour.
Average batch size = 25 parts.
Average nonoperational time = 10 hour.
9) The average of 20 new orders is started through a certain factory each month. On average, an
order consists of 50 parts to be processed through 10 machines in the factory. The operation
time per machine per each part = 15 min. the nonoperational time per order at each machine
averages 8 hours, and the required setup time per order = 4 hour. There are 25 machines in the
factory, 80% of which are operational at any time (the other 20% are in repair or maintenance).
The plant operates 160 hour/month. However, the plant manager complaint that total of 100
overtime machine hour must be authorized each month in order to keep up with production
schedule. A) What is the MLT for an average order?
B) What is the PC (on a monthly basis), and why must the overtime be authorized?
C) What is the utilization of the plant according to the definition given in the text?
D) Determine the average level of WIP in the plant.
E) Determine the WIP ratio & TIP ratio.
10) The mean time between failures for a certain production machine is 250 hour, and the mean
time to repair is 6 hour. Determine the availability of the machine.
11) There are 9 machines in the automatic lathe section of certain machine shop. The setup time on
an automatic lathe averages 6 hour. The average batch size for parts processed through section
is 90. The average operation time is 8.0 min. Under shop rules, an operator is permitted to be
assigned to run up to 3 machines. Accordingly, there are 3 operators in the section for the 9
lathes. In addition to the lathe operators, there are 2 setup workers who perform machine setup
exclusively. These setup workers kept busy for the full shift. The section runs 8 hour shift per
day, 6 days per week. However, an average of 15% of the production time lost due to machine
breakdowns. Scrap losses are negligible. The production control manager claims that the
capacity of the section should be 1836 pieces per week. However, the actual output averages
only 1440 units per week. What is the problem? Recommend a solution.
12) Briefly explain the part classification n coding?
13) Briefly explain the production flow analysis?
14) Write short note on a) part family b) Cellular manufacturing?
15) Define group technology & list any 5 advantages?
16) With block diagram explain FMS work station?
17) Briefly explain material handling & storage?
18) Briefly explain computer control system in FMS?
19) Define automated flow line & explain symbols used in automated flow line?
20) Briefly explain the method of work part transport?
21) With a neat sketch explain the transport mechanism used in automated flow line?
22) Briefly explain the function of buffer storage?
23) Explain the control function used which employed in automated flow line?
24) Briefly explain the automation techniques used for machining operation?
25) List the design & fabrication consideration of automated flow line?
26) Suppose that a 10 station transfer machine is under consideration to produce a component used
in a pump. The item is currently produced by more conventional means, but demand for the
item cannot be met. The manufacturing engineering department has estimated that the ideal
cycle time will be Tc=1.0min. from similar transfer lines, it is estimated that breakdown of all
types will occur with a frequency, F=0.10 breakdowns/cycle,& that the avg down time/line stop
will be 6.0mins.the scrap rate for the current conventional processing method is 5% & this is
considered a good estimate for the transfer line. The starting casting for the component costs
$1.50 each & it will cost $60.0/hour or $1/min to operate the transfer line. Cutting tool are
estimated to cost $0.15/work part.
Using the foregoing data, it is desired to compute the following measure of line performance.
A) Production rate
B) Number of hours required to meet a demand of 1500 units/week.
C) Line efficiency.
D) Cost/unit produced.
 27) In a 10 station transfer line, the probability that a station break down will occur for a given work
part is equal to 0.01. This probability is the same for all 10 stations. Determine the frequency of line
stops/cycle on this flow line using UBA.

28)Suppose that the flow line under consideration here has 16 stations with cycle time of 15
secs(assume that all stations have roughly equal process times).When station break down occur , the
avg downtime is 2 min. the breakdown frequencies for each station are presented in the following
table.

Station Pi Station pi
1 0.01 9 0.03
2 0.02 10 0.01
3 0.01 11 0.02
4 0.03 12 0.02
5 0.02 13 0.02
6 0.04 14 0.01
7 0.01 15 0.03
8 0.01 16 0.01
We want to consider the relative performances, when the line is separated into 2, 3 or 4 stages.

29) An 8 station rotary indexing machine operates with an ideal cycle time of 20 sec. the frequency of
line stop occurrences is 0.06 sec per cycle on the average. when a stop occurs it takes an average of
3min to make a repairs, determine the following

a) Average production time Tp

b) Average production rate Rp
c) Line efficiency E
d) Proportion of down time D
30) Assume that the frequency of line stop occurrences in problem 33 is due to random
mechanical and electrical failures on the line. Suppose, in addition to the foregoing reasons for
line stops, that the workstations tools must be reset and/or changed at regular intervals. This
procedure is performed every 200 cycles. Compute costs associated with the operation of the
indexing machine are as follows:
Cost of work part = $0.35/work piece
Cost to operate the line = $0.50/min
Cost of disposable tooling = $0.02/work piece
Compute the average cost per workpiece produced off the rotary indexing machine.
31) The following data apply to a 12-station in-line transfer machine:
P=0.01 (all station have an equal probability of failure)
Tc=0.3min
Td=3.0min
Using the upper bound approach, compute the following for the transfer machine:
a) F, the frequency of line stops.
b) Rp, the average production rate.
 c) E, the line efficiency.
) a circular indexing machine performs 10 assembly operations at 10 separate stations. The
cycle time, including transfer time between stations, is 10 sec. stations break down with a
probability p=0.007, which can be considered equal for all 10 stations. When these work
stoppages occur, it takes an average of 2 min to correct the fault. Parts are not normally
removed from the machine when these stops occur. Compute the proportion of downtime,
the efficiency, and the production rate of this circular indexing machine.
32) A transfer line has 6 stations as follows:

station Operation Pi Process time(min)

1 Load part 0 0.78
2 Drill three holes 0.02 1.25
3 Ream 2 holes 0.01 0.90
4 Tap 2 holes 0.04 1.42
5 Mill flats 0.01 1.42
6 Unload part 0 0.45
The time to transfer between stations=0.28min. if the part stops due to a jam in the line, it is
removed as defective. It takes an average of 8min to determine the fault and correct the
problem and r3emove the part. Also, there is a scheduled tool change every 40 parts which
takes 6 min to complete. There are 20,000 parts to be started onto the transfer machine.
A) How many defective parts will be removed from the line?
B) How many total hours will be consumed in the manufacturing process?
C) Find the proportion of downtime.
D) Find the rate of production of acceptable parts.

33)a 23 station transfer line has been logged for 5 days(a total of 2400 min). During this
time, there were a total of 158 downtime occurrences on this line. The accompanying table
identifies the type of down time occurrence, how many occurrences and how much time for
the type of occurrence total.

Type of occurrence Number of occurrence Total minute lost

Associates with station 132 793
Total related causes at 104 520
station
Mechanical failure at station 21 189
Other miscellaneous station 7 84
failure
Associated with transfer 26 78
mechanism
34) an 8 station transfer line as the following operation at each station; also given are the
processing time & frequency of line stops for each station. During the observation period
there were 2000 parts completed.

Station Process Process time(min) Breakdown

 1 Load part 0.40 0
2 Mill top 0.85 22
3 Mill sides 1.10 31
4 Drill two holes 0.60 47
5 Ream two holes 0.40 8
6 Drill six holes 0.90 58
7 Tap six holes 0.75 84
8 Unload part 0.50 0
Also influencing the cycle time is the operation of the transfer mechanism, which take 0.15
min each cycle. When breakdowns occur it takes an average of 7.00 min to make repair and
get the line operating again. Assume that UBA is operative in your analysis for the following;
a) Determine the average production time per piece and the hourly production rate for this
transfer line.
b) What is the up time efficiency of the line and the proportion downtime?
c) How many hours required to produce 2000 parts?
27) How many defective parts will be removed from the line?
28) How many total hours will be consumed in the manufacturing process?
29) Find the proportion of downtime.
30) Find the rate of production of acceptable parts.
31) Briefly explain the concept of partial automation?
32) Briefly explain assembly process & assembly system?
33) A manual production flow line is arranged with 6 stations and a conveyer system is used move
parts along the line. The belt speed is 4ft/min and the spacing of raw workparts along the line is
one every 3 ft. the total line length is 30 ft, hence each station length=5ft. determine the
following a) feed rate Fp. b) Tolerance time Tt. C) theoretical cycle time Tc
34) A manual assembly line is to be designed with a production rate of 100 completed
assemblies/hour. The line will have 8 stations & the length of each station is 1.0m. The minimum
allowable tolerance time is to be 2.0min. With the line is figured to have a uptime efficiency of
97% (estimated for previous similar lines), determine following parameters for the line.
a) Ideal cycle time Tc.
b) Conveyor speed Vc.
c) Feed rate Fp.
d) Part spacing Sp along the belt.
35) The following list defines the presidence relationships and element times for a new model toy

Element Tc(min) Immediate predecessors

1 0.5 -
2 0.3 1
3 0.8 1
4 0.2 2
5 0.1 2
6 0.6 3
7 0.4 4,5
 8 0.5 3,5
9 0.3 7,8
10 0.6 6,9
a) Construct the precedence diagram for this job
b) If the ideal cycle time is to be 1min, what is the theoretical minimum number of stations
required to minimize the balance delay
c) Compute the balance delay for the answer found in part b.
36) Solve problem 35 using kill bridge and westor method
37) Solve problem by 35 using ranked positional weights method
38) The proposal has been submitted to replace a group of assembely workers, each working
individually, with an assembely line. The following table gives the individual work elements

Element Te(min) Immediate predecessors

1 1.0 -
2 0.5 -
3 0.8 1,2
4 0.3 2
5 1.2 3
6 0.2 3,4
7 0.5 4
8 1.5 5,6,7
The demand rate for this job is 1600 units/week (assume 40 hrs/week) and the current number
of operators required to meet this demand is 8 using the individual manual workers.
a) Construct the precedence diagram from the data provided on work elements
b) Use the largest candidate rule to assign work elements to station what is the balance delay
for this solution?
c) The initial cost to install the assembly line is 20,000$. If the hourly rate for workers is $
5.00/hour, will the assembly line be justified using a 3 years’ service life? Assume 50 weeks
per year use rate of return=10%
39) Briefly explain the concept computerized line balancing method?

40) Briefly explain any 5 ways to improve the line balancing?