Process Evaluation Assignment

ISEN4821. F2020

Assignment: A case Study in Process Analysis and Design

Product A is formed by assembling three parts (P1, P2, and P3) together. All three
parts are manufactured by Alodine corp. The Co. ships the product unassembled to
the customers. Only three types of machines (M1, M2, and M3) are used in the
manufacturing operations. Parts P1 and P2 are made of plastics and weight 0.8 and
0.4 lbs. each respectively. Part P3 is made of aluminum and weigh 0.5 lbs. Based
on The Sales Department estimates, demand for the product in the next 5 to 10 years
will be about 15000 units per month. In addition, the following manufacturing data
is made available:

Product Sequence of % Scrap % Scrap %Scrap

machines From M1 From M2 From M3
P1 M2➔ M3 3 2 3
P2 M1➔ M3 0.5 1.2 2
P3 M1➔M2➔M3 0.09 0.06 0.04
Standard Time:
Machine ➔ M1 M2 M3
Standard Times (hrs./unit) ➔ 0.04 0.07 0.09

What is needed?
The company intends to produce each product at least once a week. This will avoid buildup of
large inventories of parts. On the basis of the following assumptions determine:
1). Number of machines of each type required.
2). Total amount (lbs) of scrap produced/week.
3). Number of workers required.
4). Bill of Material and a complete process flow chart

ASSUMPTIONS:
a). One year of work means; 8 hrs./day, 5days/week, and 50 weeks/year.
b). Set-up times are: 60 min., 60 min., and 90 min. for M1, M2, and M3 respective
c). Machine availability (for all three machines) is 90% of time.
d). M2 and M3 each need 1 operator, but M1 needs two Operators. The operators are needed only
when machines are operating.
e). The Co. desires to minimize the number of machines required for the operations (minimum
initial investment). On that basis you may plan to use up to 20% overtime.
d). Labor cost per finished unit of the product