9

SINGLE STATION MANUFACTURING CELL & AUTOMATED

PRODUCTION LINE
Please answer the following questions and include the references.
1. Explain the following as completely as possible and followed with the application in
industries!
(a) Single Station Manned Workstation.
(b) Single-Station Automated Cells.

[Guide: may include definition, reasoning, types, application, illustrations, etc.]

2. A total of 10000 stampings must be produced in the press department during the next 5
days. Manually operated processes (one operator per press) will be used to complete the job
and the cycle time is 24 sec. Each press must be set up with a punch and die set before
production starts. setup time is 5 hr and availability is assumed to be 99%. How many
processes and operators must be devoted to this production during 5 days if there are 7.5 hr
of available time per machine per day?
3. A stamping plant must supply an automotive final assembly plant with sheet metal
stampings. The plant operates one 8-hr shift for 250 days/yr and must produce 6,000,000
good quality stampings annually. Batch size = 8,000 good stampings produced per batch.
Scrap rate = 5%. On average it takes 4.0 sec to produce each stamping when the presses are
running. Before each batch, the press must be set up, and that takes 2.5 hr per setup.
Availability of the presses is 95% during production and 100% during setup. How many
stamping presses will be required to accomplish the specified production?
4. An emergency situation has arisen in the milling department, because the ship carrying a
certain quantity of a required part from an overseas supplier sank on Friday evening.
A certain number of machines in the department must therefore be dedicated to the
production of this part during the next week. A total of 6000 of these parts must be
produced, and the production cycle time per part = 20 min. Each milling machine used for
this rush job must first be set up, which takes 5.0 hr. A scrap rate of 2% can be expected.
Assume availability = 100%.
(a) If the production week consists of 10 shifts at 8.0 hr/ shift, how many machines will be
required?
(b) It so happens that only two milling machines can be spared for this emergency job, due
to other priority jobs in the department. To cope with the emergency situation, plant
management has authorized 3 shifts operation for six days next week. Can the 6,000
replacement parts be completed within these constraints?

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