ID# Surname Name

Personal Code

Politecnico di Milano – Industrial Technologies Course
Exam 19 July 2017

Exchange Student (e.g. Yes No

Erasmus)
From (please, fill in your
university)

RULES – PLEASE READ THEM BEFORE STARTING

• Please, check on your paper your name, surname and personal code.
• Please, be schematic and short! One page per question is enough! Don’t be verbose as Italians J.
• In solving exercises, please state clearly the main steps of the solution.
• You CAN NOT use any materials (e.g. books, notes, etc.). Trespassers will be prosecuted!
• THIS IS NOT THE TIME TO ASK, BUT TO ANSWER! The professor will not reply to your questions. If
you have any doubt, please mention it on your text.
• Please, use TWO DECIMAL NUMBERS after comma.
• Available time 120 minutes.

Instructions (VERY IMPORTANT)

• Please, read the last number of your personal code ()

• If it is between 0 and 4, you are in the group X
• If it is between 5 and 9, you are in the group Y
• Pay attention to questions 4 and 6, in which you have the GAMMA coefficient, which is used to multiply
some elements relevant to questions 4 and 6: GAMMA is set to 1 for group X, and to 2 for group Y.

The final answers for practical questions must be reported within the boxes. The full procedure for
solving the exercise must be clearly reported on the paper.

YOU MUST USE only this text. None other papers could be used!

Please select here your

Exam GROUP X Y
(read rules above)

GAMMA is ……………..

You are in room

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Question 1 (5 points)
How can you define a process plant? Please, describe the general features of such types of production
systems. Can you list at least 3 examples of industries/sectors working as process-based productions?

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Question 2 (5 points)
How manufacturing cells should be designed? Which are the main design methods? How do they work? Be
schematic, but comprehensive!

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Question 3 (5 points)
EIASME is a medium-sized manufacturing company, with several production plants spread around Europe,
resulting from several acquisitions done in the last 5 years. It produces plastic components for the automotive
industry.
EIASME is currently registering an increase of demand and it is planning to add an extra stamping department
to one of its plants, in Poland. The stamping department should be composed by 5 main types of machines
(M1, M2, M3, M4, M5) and it should be able to deliver 6 main product families (P1, P2, P3, P4, P5, P6). The
production layout should be organised as job shop. Processing times of the mentioned products are hereafter
defined [data in minutes]:

• P1: (M1, 8), (M2, 8)

• P2: (M3, 7), (M4, 7), (M5, 10)
• P3: (M1, 2), (M2, 5), (M5, 2)
• P4: (M1, 3), (M2, 2), (M3, 5), (M5, 13)
• P5: (M3, 3), (M4, 2), (M5, 8)
• P6: (M4, 10), (M5, 12)

Setup times are based on the different machines: M1 takes normally 10 minutes / setup, M2 30 minutes/setup,
M3 20 minutes/setup, M4 10 minutes/setup, M5 10 minutes/setup.

The company has decided to work with a pre-defined lot dimensions: P1 should be produced in batches of
100 pieces, P2 200 pieces, P3 300 pieces, P4 400 pieces, P5 500 pieces, P6 600 pieces.

The yearly demand of the different products should be the following: P1 5.000 pieces/year (x GAMMA), P2
15.000 pieces/year (x GAMMA), P3 18.000 pieces/year (x GAMMA), P4 12.000 pieces/year (x GAMMA),
P5 2.500 pieces/year (x GAMMA), P6 3.000 pieces (x GAMMA).

The production system will work 2 shifts of 8 hours per day, 300 days/year. The following coefficients should
be used in the design of the job shop: TR = 0.9 (Trial Rate), SR = 0.05 (Scrap Rate), A = 0.92 (Availability),
HC = 0.85 (Human Coefficient), SE = 0.8 (Scheduling Efficiency).

Please, design the job shop using the provided information. Use the available blank pages for the solution
and present clearly your design decisions in the table below. Take care to the GAMMA coefficient (see rules
in the first page).

SOLUTION

Shop M1 M2 M3 M4 M5
Number of
machines

Please, provide hereafter the full procedure for solving the exercise:

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Question 4 (5 points)
The board of the EIASME company is interested to evaluate the alternative of a production layout organised
in manufacturing cells. Starting from the data of the first exercise, please define the reference
product/machine matrix and determine a feasible cell-based layout. For the definition of the cells, please use
the ROC (Rank Order Clustering) technique.

SOLUTION

a) Starting product/matrix table

b) Final product/matrix table, after the application of the ROC technique.

a) Define the manufacturing cells which should be installed.

Please, provide hereafter the full procedure for solving the exercise:

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Question 5 (5 points)
You have to design a continuous flow line for the production of bulk material. The data are:
• Production target: 30.000 ton (x GAMMA, see rules above!)
• Theoretical production capacity: 22,00 ton/day
• Opening days: 260 days/year, 24h/day
• Scrap Rate (SR): 0,065
• Availability (A): 0,955
• Scheduling Efficiency (SE): 0,93

Your objective is to calculate: the actual production capacity; the number of continuous flow lines to install,
and the average saturation. Take care to GAMMA coefficient!

SOLUTION

a) Actual production capacity

b) Number of continuous flow lines

c) Average saturation

Please, provide the full procedure for solving the exercise

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Question 6 (5 points)
Consider the product below (LENNART drawers). See the provided assembly instructions (from IKEA website
®). Depict the assembly graph for this product (use the numbers of the operations in the instructions below).
Take care: the full product should be assembled! If you have any comment, please write it in the next page.

Please, draw the complete assembly graph in this space: