Test Series: 1

Manufacturing system design (MEL 361)

Time: 50 Min Max. Marks: 20

Instructions:

1) All questions are compulsory

2) Please make the assumption, if needed.

Q.1 What is an automation migration strategy? What are the three phases of a typical
automation migration strategy, please briefly discuss with an appropriate example? (2
Marks)

Q.2 What is the difference between single model production line and mixed model
production line. (2 Marks)

Q.3 A product line has two models: X and Y. Model X consists of 3 components: a,b and c.
The number of processing operations required to produce these three components are 5,10
and 15 respectively. Model Y consists of 3 components: d, e and f. The number of processing
operations required to produce these three components are 2,4 and 6 respectively. The annual
quantity of Model X is 2,000 units and of Model Y is 3,000 units. Determine the total number
of ( a) components and ( b) processing operations associated with these two models. ( 4
Marks)

Q.4 The ABC Company is planning to introduce a new product line and will build a new
factory to produce the parts and assembly the final products for the product line. The new
product line will include 90 different models. Annual production of each model is expected to
be 1200 units. Each product will be assembled of 600 components. All processing of parts
and assembly of products will be accomplished in one factory. There are an average of 10
processing steps required to produce each component, and each processing step takes 30
sec.(includes an allowance for setup time and part handling). Each final unit of product takes
3.0 hours to assemble. All processing operations are performed at work cells that each
includes a production machine and a human worker. Products are assembled on single
workstations consisting of two workers each. If each work cell and each workstation require
200 ft2, and the factory operates three shift (6000 hr/yr), determine: (a) how many production
operations, (b) how much floorspace, and (c) how many workers will be required in the plant.
(4 marks)

Q.5 Average setup time on a certain production machine is 6.0 hr. Average batch size is 40
parts, and average operation cycle time is 2.5 min. The reliability of this machine is
characterized by mean time between failures of 40 hr and a mean time to repair of 35 min.
Determine:
(a) if availability is ignored, what is the average hourly production rate of the machine?
(b) Taking into account the availability of the machine, determine its average hourly
production rate
(c) Suppose that availability only applied during the actual run time of the machine and not
the setup time. Determine the average hourly production rate of the machine under this
scenario. (4 marks)

Q.6 (Part 1): Suppose a turning operation is to be performed with HSS tooling on mild steel,
with Taylor tool life (VTn=K) parameters n= 0.125, C = 70 m/min. Workpart length = 500
mm and diameter = 100 mm. Feed = 0.25 mm/rev. Handling time per piece = 5.0 min, and
tool change time = 2.0 min. Cost of machine and operator = $30/hr, and tooling cost= $3 per
cutting edge. Find: (a) cutting speed for maximum production rate, and (b) cutting speed for
minimum cost.

(Part 2): Determine the hourly production rate and cost per piece for the two cutting speeds
computed in the Part 1. (4 marks)