King Fahd University of Petroleum & Minerals

Mechanical Engineering Department

ME 322: MANUFACTURING PROCESSES

Semester (213)
Homework # 1
Assigned Saturday, June 11, 2022
Due on Saturday 18th June 2022 on BB (before 11:59 pm). Late submission or
submission by email will not be considered

Name: _________________________________ ID#: ___________________________

Problems Marks Grades Obtained

1 25

2 25

3 25

4 25

Total 100

IMPORTANT
 Write your name and ID# on this cover page and include it with the
solution file and save it as PDF file. 10% deduction for missing cover
page
 Name the PDF file as “HW#-ID#.pdf” (e.g. HW1-202012345.pdf).
 Upload the PDF file on M322-BlackBoard under the Assignments
section.
 You will have 2 attempts to upload your solution.
 (IMPORTANT: Plagiarism, i.e. copying HW from others’ work, will
grant you ZERO in the HW).
Problem 1:
A machining factory is using batch production to manage its production operations. Knowing
that the estimated scrap rate of the machining process is 3%, it was decided that 65 good parts
should be produced from each batch. During the machining process, it is important to change
the SR20 cutting tool after every 15 parts. The tool changing time = 2 min. The machining
time for each part = 3 min, handling time = 2 min, and the setup time for the machine = 1hr.
If the starting work part costs SR10 and the labor and equipment hourly rate included
overhead = SR150. Determine
a) The production rate of good parts (10 Points)
b) The cost of the finished good part. (10 Points)
c) How many hours are required to complete 200 good parts? (5 Points)

Problem 2:
An injection-molding machine is used to make plastic bottles for drinking water. The process
used a mold with 20 cavities so each 5-minute injection cycle will make 20 bottles. The cost
of the mold is SR10,000 and it is designed to make 01million bottles before it becomes
obsolete. This type of mold needs 20 minutes of regular maintenance after the injection of
1000 bottles. It takes 1 hour to prepare the injection machine to inject this certain size of
bottles and the polymeric material that is used to make one battle costs SR0.05. The labor
hourly wage is SR25 with a 30% overhead cost. The injection machine costs SR30 per hour
including overhead costs. On average, the injection machine is 98% available and produces
1% defective parts. The handling time can be ignored. For an order of 100,000 bottles find
the following
a) The production rate (bottle/hr) (13 pts)
b) The cost of the order (12 pts)
c) The cost of each bottle. (5 pts)

Problem 3:
An order of 200 gears is to be made using the milling process. Each gear is made from a
starting material that costs SR50 and it takes 5 minutes for each gear as a handling time. The
setup time for the milling machine is 30 minutes, while the machining time for each gear is
30 minutes. Each cutting tool used in the process costs SR1500 and is used to machine 04
gears before it needs to be replaced with a new tool. The tool change time is 5 minutes. The
equipment and machinist both cost SR250/hr (C L + Ceq =SR250/hr), the scrape rate of this
milling process is 4% and the milling machine is always available, then find
a) Cycle time (min/piece) (5 pts)
b) Batch time for a 200 gear ordered (hr) (5 pts)
c) The production time (min/piece) (5 pts)
d) If each gear will be sold with 50% profit, what will be the selling price for the order of the
200 gears? (10 pts)

Problem 4:
A Batch of 40 good workpieces is to be produced using a sand casting process with a starting material
that costs SR40 a piece. The time it takes to fill the mold is 10 seconds, while the solidification time is
1 minute. The casting is removed from the sand mold in 5 seconds. The sand used to make the mold
costs SR100 and can be used to make 100 molds before it needs to be replaced by new sand. Making
the mold will take 20 minutes. Neglecting the melting process and assuming 5% scrap rate, then
determine:
a) The production rate of the casting process (10 pts)
b) The cost of each produce part given that (10 pts)
 the hourly wage rate of the operator = SR100/hr, and the applicable labor overhead rate = 60%, &
 the hourly equipment cost rate = SR20/hr; which includes overhead.