WEEK 4 TUTO

Example 1

 The workload consist of 800 shafts at 11.5 min/shaft

 WL = 800 shafts (11.5 min/shaft) = 9200 min = 153.33 hr
 Time available per lathe during the week, AT = 40 hr
 n = WL/AT= 153.33hr / 40hr = 3.83 lathes → 4 lathes
Example 2
 The number of hours available on any lathe used for the shaft order is
reduced by the setup time. Example, lathe setup requires 3.5 hr, then
how many lathes are required?
 AT = 40 – 3.5 = 36.5 hr (reduced by setup time)
 n = 153.33hr / 36.5hr= 4.20 lathes → 5 lathes
 Considering 5 lathes, then the actual utilization is;
U = 4.20 / 5 = 0.840 (84.0%)
 If we maintain 4 lathes, we will need overtime;
OT = [3.5+(153.33/4)] - 40 = 1.83 hr
 Since there are 4 lathes;
total 4(1.83 hr) = 7.33 hr for four machine operators

 E.g. 20 batches (of different lathes) will be produced with average

batch size is 40 parts.
 We can determine the workload for the 20 setups and the workload for
20 production batches
 WL = 20(3.5) + 20(40)(11.5/60) = 223.33 hr
 Given that each lathe is available 40 hr/wk
 n= 223.33hr / 40hr = 5.58 lathes → 6 lathes
Example 4
A total of 7000 stamping must be produced in the press department
during the next three days. Manually operated presses will be used to
complete the job and the cycle time is 27 sec. Each press must be set up
before production starts. Setup time for this job is 2.0 hr. How many
presses and operators must be devoted to this production during the
three days, if there are 7.5 hours of available time per day?
Example 6
A certain type of machine will be used to produce three products: A, B, and C. Sales forecasts for these
products are: 52,000, 65,000, and 70,000 units per year, respectively. Production rates for the three products
are, respectively, 12, 15, and 10 pc/hr; and scrap rates are, respectively, 5%, 7%, and 9%. The plant will
operate 50 weeks per year, 10 shifts per week, and 8 hours per shift. It is anticipated that production
machines of this type will be down for repairs on average 10 percent of the time. How many machines will
be required to meet demand?
Machine Cluster
Example 1- How many machines for one worker?
 A group of CNC machines operating on a semi-automatic machining cycle, with machining cycle time =
2.75 min. One worker is required to unloading/loading of parts at the end of cycle, taking 25 sec. How many
machines one worker can service if walking between machines take average of 20sec; note that machine idle
time is NOT allowed.

 Tm = 2.75 min, Ts = 25 sec (0.4167 min), Tr = 20 sec (0.3333 min)

n  (0.4167 2.75)/(0.41670.333)  4.22machines

 Since no machine idle time is allowed, the number of machine is 4. In this case worker will have idle time.

 Worker idle time =

 In contrast, if machine idle time is allowed, then n = 5. In this case the worker will have no idle time.
Example 2

The CNC grinding section has a large number of machines devoted to grinding shafts for the automotive
industry. The grinding machine cycle takes 3.6 min. At the end of this cycle an operator must be present to
unload and load parts, which takes 40 sec. (ai) Determine how many grinding machines the worker can
service if it takes 20 sec to walk between the machines and no machine idle time is allowed, (aii) if no
worker idle time is allowed?. (b) For (ai), how many seconds during the work cycle is the worker idle? (c)
What is the hourly production rate of this machine cluster?
Example 3

In a machine cluster, the appropriate number of production machines to assign to the worker is to be
determined. Let n = the number of machines. Each production machine is identical and has an automatic
processing time Tm = 4.0 min. The servicing time Ts = 12 sec for each machine. The full cycle time for
each machine in the cell is Tc = Ts + Tm. The repositioning time for the worker is given by Tr = 5 + 3n,
where Tr is in sec. Tr increases with n because the distance between machines increases with more
machines. (a) Determine the maximum number of machines in the cell if no machine idle time is allowed.
For your answer, compute (b) the cycle time and (c) the worker idle time expressed as a percent of the cycle
time?
Example 4

An industrial robot will service n production machines in a machine cluster. Each production machine is
identical and has an automatic processing time Tm = 130 sec. The robot servicing and repositioning time for
each machine is given by the equation (Ts + Tr ) = 15 + 4n, where Ts is the servicing time (sec), Tr is the
repositioning time (sec), and n = number of machines that the robot services. (Ts + Tr ) increases with n
because more time is needed to reposition the robot arm as n increases. The full cycle time for each machine
in the cell is Tc = Ts + Tm. (a) Determine the maximum number of machines in the cell such that machines
are not kept waiting. For your answer, (b) what is the machine cycle time, and (c) what is the robot idle time
expressed as a percent of the cycle time Tc?