9

SINGLE STATION MANUFACTURING CELL & AUTOMATED

PRODUCTION LINE
Muhammad Ardhan Anshari
02411940000179
Class D

Answer
1. Explain the following as completely as possible and followed with the application in industries!
(a) Single Station Manned Workstation.

" One worker examines a manufacturing unit (the most common model)"

Production methods are the most widely used, especially in job shops and production
batch

Reason for use:

- The quickest execution period
- The smallest initial capital investment
- Easiest to set up and operate
- Typically, the lowest unit cost for short production runs
- Most adaptable for changing parts or products

• The operator operates a standard machine tool

- Operators load and unload parts, operate machines
- The machine is operated manually
• Operators operate semi-automatic machines
- The operator performs part loading and unloading, starting a semi-automatic process cycle
- The operator does not have to be in place continuously during the processing cycle
• Operators use manual equipment or portable automatic equipment on a
specific location.

(b) Single-Station Automated Cells.

“A fully automatic processing system that can run for longer periods of time without the need
for an operator. "

Operator presence is not required unless attendance is periodic

Reasons for implementation:
- Less labour needs
- Simplest and cheapest automation system to introduce
- Output rate is usually higher than the production cell with the operator
- As a first step to integrating a multi-station automation system

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?

Q : 1000

Tc: 24 sec

WL = ∑Q Tc

WL = (1000 x 24/60) + (5 x 60) n

WL = 4000 + 300 n minutes

WL = 66,67 + 5 n hours

Time available

AT = H x AU

AT = 5 x 7,5

AT = 37,5 hours

66,67 + 5 n = 37,5 n

32,5 n = 66,67

n = 2,05

it must be devoted around 2,05 or 2 processes and operators

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?

Q : 6.000.000
stampings Tc : 4
sec
Scrap Rate : 5 %

WL = Q x Tc / 1 - q
WL = 6.000.000 - (4/3600) / 1 - 0,05
WL = 7.017,55 hour per year

AT = H x AU
AT = 250 x 8 x 0,95
AT = 1900 hour per year

Number Batches/Year
6.000.000 / 8.000 = 750 setups

WL = 750 x 2,5
WL = 1875 hour per year

AT = 250 x 8
AT = 2000 hour per year

n = (7017,55 / 1900) + (1875 + 2000)

n = 3,69 + 0,94
n = 4,63

it is required 4,63 or 5 presses

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?

Q : 6.000
Tc: 20
min
Scrap
Rate : 2%

WL = Q x Tc / 1 - q
WL = 6.000 (20/60)/ 1 - 0,02
WL = 2040,81 hour per week
10 shift ; 8 hour per shift
AT = (10 x 8) - 5 = 75 hour per week per machine

n = 2040,81 / 75
n = 27,2 hour per week per machine

it is required 27,2 or 27 milling machines

(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?

AT = (6 x 3 x 8) - 5
AT = 139 hour per week per machine

n = 2040,81 / 139
n = 14,6

it is required 14,5 or 15 milling machines to completed the job