2.9 An assembly chart for a simple gate valve in shown in Figure P2.9 (a).

Processing Information for the gate valve is

given in Figure P2.9 (b). The following scheduling information is available.
(1) All designing and planning for the production of the gate valves has been completed.
(2) Patterns for the various cast parts can be obtained in 4 working days.
(3) Two days are required for the production of castings. Castings cannot be produced in the foundry until after
receipt of the patterns.
(4) Various sizes of bar stock can be obtained from a local metal supply house 3 days after orders for stock have
been placed.
(5) Nuts, screws, packing, etc., can be obtained in 3 days.
(6) The design engineers have specified that the body bushing, and handle be made of cast bronze, and that the
cap and stem of the valve be machined from standard brass bar stock.
(7) The bill of material indicates that the fiber packing and the nuts are purchased parts.

The Plant Problem:

#1

Body
A-1

#2

Bushing

Assemble Stem and

Bushing to Body

SA-1

#3

#4

Stem

Packing
SA-2

#5

#6

A-2

Cap

Handle
A-3

#7

Assemble Cap

Assemble Handle

Nut

Figure P2.9 (a)

Final Inspection

Parts
Body
Bushing
Stem
Fiber packing
Cap
Handle
Nut

Part No.
001
002
003
004
005
006
007

Material
Cast Bronze
Cast Bronze
3/8 in. bar stock
(Purchased part)
3/4 in. hex bar stock
Cast Bronze
(Purchased part)

Assembly Operations

No

Operation

Machine

1
2
3
4

Final Assembly
Clean
Inspect (Pressure test)
Pack in boxes

Work Bench
Solvent tank
Water test stand
Work Bench

Standard
(min / part)
2.00
0.60
1.20
0.12

Figure P2.9 (b)

Part No.

Operation No.

001

001-1
002-2
001-3

002

002-1
002-2
002-3

003

003-1

005

005-1

Cast
Clean
Machine Thread
and face three
surface
Cast
Clean
Machine all I.D. and
O.D.
Machine all surface
and cut off
Machine all surface

006

006-1
006-2
006-3
006-4

Cast
Clean
Machine two surface
Broach square hole

Bench mold
Tumble barrel
Turret lathe

Standard Time
(min/part)
1.50
0.40
2.40

Bench mold
Tumble barrel
Turret lathe

0.75
0.20
1.00

Automatic screw
machine
Automatic screw
machine
Bench mold
Tumble barrel
Turret lathe
Broach

0.30
0.12
1.20
0.30
0.75
0.75

Note: 100% inspection is required for all fabricated parts prior to delivery to final assembly.
(8) The machine shop estimates the following fabrication times for processing batches of 500 parts:
Body: 3 days
Bushing: 3 days
Stem: 1 day
Cap: 1 day
Handle: 2 days
Construct an operation process chart, precedence diagram, route sheets, and a Gantt chart for the production of
the gate valve. Develop a summary of equipment requirements for the production of 500 gate valves per hour.

2.10 Eight parts (A to H) are to be manufactured and assembled to produce two products (X and Y). The processing
sequence for the parts and assembled sequences for the products are given below. The daily production rate for product
X is 400 and for product Y is 600.
(a) Determine the daily production rates for each part.
(b) Design a product layout for manufacturing and assembling each product.
(c) Design a process layout for manufacturing both products.
(d) Design a group layout for manufacturing the two products.
(e) Construct a from-to chart for the daily flow of parts between processes.
(f) Construct an activity relationship chart for each product and a combined REL chart for the two products.
(g) Using the traditional SLP approach, design a REL diagram for each REL chart constructed in part (f).
The Plant Layout Problem
Part
A
B
C
D
E
F
G
H

Processing sequence (Grouped by

machine)
(cast), (tumble), (mill), (turn, thread, drill, tap)
(cast), (tumble), (mill), (turn, drill, tap)
(turn, thread)
(punch), (bend), (drill)
(punch), (bend), (drill)
(punch), (bend), (drill)
(turn)
(turn, thread)

Machine
Bench mold
Tumble mill
Milling machine
Turret lathe
Automatic screw
machine
Drill press
Punch press
Press brake

A
3.0
1.1
2.4
3.5
--

B
4.25
0.7
3.4
1.7
--

----1.3

------

----

----

----

1.5
0.3
0.8

Parts
E
------

2.2
0.5
1.2

------

----0.6

----0.9

1.1
0.4
1.1

----

----