MANDALAY TECHNOLOGICAL UNIVERSITY

DEPARTMENT OF MECHATRONIC ENGINEERING

McE -42052 FMS Tutorial- I 27.8.2019 (Tue)
Sr.No. Questions Marks
1. Four machines belong to a GT machine cell. Machine 1 and machine 2 are identical and 10
are used to feed machine 3, which is the main machine in the cell. The output of machine
3 feeds into machine 4. The cell is set up to produce a family of 5 parts (A, B, C, D and
E). The operation times for each part at each machine are given in the following table.

The products are produced in the ratio 4:3:2:2:1. If the hours worked per week are 35,
determine how many of each product will be made by the cell? What are the utilization
of the main machine and the utilization of the cell?
Solution
Given: Production-ratio = 4:3:2:2:1
Time available per week = 35 hr. /week x 60 min/hr. = 2100 min/week
Computing time to produce units in given ratio,
Time of Machine 1 = 4 ( 4 ) + 3 ( 15 ) + 2 ( 26 ) + 2 ( 15 ) + 1 (8) = 151 min
Since machine 1 and machine 2 are identical,
Time of Machine 2 = 151 min
Time of Machine 3 = 4 (15 ) + 3 ( 18 ) + 2 ( 20 ) + 2 ( 20 ) + 1 ( 16 ) = 210 min
Time of Machine 4 = 4 (10 ) + 3 ( 7 ) + 2 ( 15 ) + 2 ( 10) + 1 ( 10 ) = 121 min
Number of cycles to produce the products in the ratio given is
Time available 2100 min
  10 cycles
Maximum time 210 min/ cycle

Thus, output per cycle = 10 cycles × (4 + 3 + 2 + 2 + 1) pc. /cycles = 120 pc.

For 10 cycles,
Number of product 1 (A) = 4 × 10 = 40 pc.
Number of product 2 (B) = 3 × 10 = 30 pc.
Number of product 3 (C) = 2 × 10 = 20 pc.
Number of product 4 (D) = 2 × 10 = 20 pc.
Number of product 5 (E) = 1 × 10 = 10 pc.

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 10  210 
Utilization of the main machine (machine 3) =  1  100%
2100

10 151
Utilization of the machine 1 and 2 =  0.719  71.9%
2100

10 121
Utilization of the machine 4 =  0.576  57.6%
2100
0.719  0.719  1  0.576 3.014
Average Utilization of the cell =   0.7535  75.35%
4 4
2. A GT cell consists of 5 machines. The from–to data for the machines are as follows: 10

( i ) Determine the logical sequence of machines according to/from ratios

(ii) Construct a flow diagram
(iii) Where do the parts enter cell and exit the cell? How many parts in each place?
Solution
To
1 2 3 4 5

1 0 10 80 0 0
2 0 0 0 85 0
From 3 0 0 0 0 0
4 70 0 20 0 0
5 0 75 0 20 0
Changing the rows and columns,
From
1 2 3 4 5
1 0 0 0 70 0
2 10 0 0 0 75
To 3 80 0 0 20 0

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 4 0 85 0 0 20
5 0 0 0 0 0
(i)
From
To-from ratio
From sum
To/From
1 2 3 4 5
1 0 0 0 70 0 70 90/70 = 1.29
2 10 0 0 0 75 85 85/85 = 1
To 3 80 0 0 20 0 100 0/100 = 0
4 0 85 0 0 20 105 90/105 = 0.86

5 0 0 0 0 0 0 95/0 = ∞
To sum 90 85 0 90 95

From To/from ratio, arranging the machines in ascending order for the machine
sequence,
The logical sequence of machines according to/from ratios is 3-4-2-1-5.
(ii) Flow diagram is
80 75

100 in 95 out
20 85 10 0
3 4 2 1 5

70
20 out
15 in

20

(iii) 100 parts enter at machine 3, 15 parts enter at machine 4, 20 parts after machine 1
leaves, and 95 parts after machine 5 leaves.
3. In order to determine the number of vehicles required to meet the demand for a 10
particular automated guided vehicle system. The system must be capable of making 60
deliveries per hour. The following are the data of performance characteristics of the
system:
Vehicle velocity = 50 m/min.
Average distance traveled per delivery = 150 m
Pick up time = 0.45 min.

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 Drop off time = 0.45 min.
Average distance traveling empty = 100 m
Traffic factor = 0.8
Determine the number of vehicles required to meet the demand of delivery. Also
determine the handling system efficiency?
Solution
Ld Le 150 100
Tv  Tl  Tu    0.45  0.45    5.9 min
v v 50 50
Tf 0.8
The number of delivery per hour per vehicle = 60   60 
Tv 5.9

 8.136 deliveries/hour/vehicle
Number of deliveries required per hour
Number of vehicle required =
Number of delieveries
hour/vehicle
= 60/8.136 = 7.374 (Approximately 8 vehicles)

 Ld   Ld   150 
  Tf    Tf    0.8 
Handling system efficiency =  v  
v    50 
 Ld Le  Tv 5.9
  Tl  Tu  
 v v 

 0.4068  40.68%
4. The oval of a top-driven carousel track has a length = 70m and width = 5m. The speed 10
of the carousel = 80 m/min. There are 150 carriers around the carousel and each carrier
has 6 bins suspended from it. For a single direction carousel and a bidirectional carousel,
compare how long it take it takes to retrieve 20 parts from the carrier if each part is in
different storage bin and random storage is used in the carousel. Also determine the
spacing between carriers and carousel. The handling time associated with retrieval is 20
seconds.
Solution

Given: Ls = 70 m, Ws = 5 m, Vc = 60 m/min, nc = 150, nb =

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 20
Th   0.333min
60

C  2  Ls  Ws   Ws  2  70  5  5  145.71m

For the single direction, the average travel distance is given by

Lr = 0.5C
And the corresponding time complete a retrieval transaction,
Tr = (0.5C/Vc) + Th
For single direction carousel, the retrieval of 20 parts would require
20Tr = 20 × (0.5 × (145.71/80) + 0.333)
Tr = 24.82 min
For the carousel capable of bi-directional travel, the corresponding average travel
distance and retrieval transaction time are
Lr = 0.25C
Tr = (0.25C/Vc) + Tc
For a bidirectional carousel, the retrieval of 20 parts would require
20Tr = 20 × (0.25 × (145.71/80) + 0.333)
Tr = 15.71 min
The spacing between carriers along the carousel is given by nc sc = C.
sc = 145.71/150 = 0.9714 m
5. A mechanized storage carousel has a length of 40 m and a width of 4.5 m. The velocity 10
of the carousel is 60 m/min., and the part handling time at the unload station is 0.40 min.
Compute the average time to retrieve a part from the system:
(a) Assuming that the system revolves in a single direction
(b) Assuming that the system revolves in both direction
Solution
Given: Ls = 40 m, Ws = 4.5 m, Vc = 60 m/min, Th = 0.40 min
For oval shape of carousel,

C  2  Ls  Ws    Ws  2  40  4.5   4.5  85.137m

(a) Assuming that the system revolves in a single direction

For the single direction, the average travel distance is given by
Lr = 0.5C
And the corresponding time complete a retrieval transaction,
Tr = (0.5C/Vc) + Th

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For single direction carousel, the average time to retrieve a part from the system is
Tr = 0.5 × (85.137/60) + 0.40
Tr = 1.109 min
(b) Assuming that the system revolves in both direction,
For the carousel capable of bi-directional travel, the corresponding average travel
distance and retrieval transaction time are
Lr = 0.25C
Tr = (0.25C/Vc) + Tc
For a bidirectional carousel, the average time to retrieve a part from the system is
Tr = 0.25 × (85.137/60) + 0.40
Tr = 0.755 min

*************** End of Questions ***************

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