DEPARTMENT OF INDUSTRIAL ENGINEERING TECHNOLOGY

MANUFACTURING SYSTEMS DESIGN

MFDMIA2

TEST I
TIME - 2hrs 26/03/2021

Answer all questions

QUESTION 1

1.1 Discuss and distinguish the different components of a modern manufacturing

system?

(6)

1.2 Differentiate mechanised, semi-automated, and automated machinery.

(6)

1.3 Highlight the key design elements of the work part transportation subsystem
in manufacturing operations. (3)

QUESTION 2

2.1 A total of 10 000 forgings are required in five (5) days. Manually operated
forge hammers are used to do the job. The cycle time is 50 secs. Set up time
for each machine is 2.0hr. Determine the total number of forge hammers to
 satisfy demand? Assume a single 8 hours shift per day?
(4)

2.2 An Industrial Engineer is required to design a cutlery production plant. The

plant will operate three (3) shifts per day, five days per week, 47 weeks per
year. Total output from the plant must be 5,000,000 pieces of utensils per
year in batches. Each batch consists of 2500 pieces. Average scrap rate is
7%. The average cycle time is 0.5 min to complete one part. The machine set
up and retooling time per batch is 4 hr. Average plant availability is estimated
at 96%. Determine the number of individual machines that will be required in
the new plant to meet demand.

(10)

QUESTION 3

An Industrial Engineer has been assigned to design an assembly line to produce

100 000 calculators per year. The assembly line will operate 8hr /shifts, five shifts
per week, 47 weeks per year. Total work content time is 25 mins. Line availability
is estimated at 95%. Determine:

3.1
a) Cycle time, Tc

(3)
b) Theoretical minimum number of workers on the line

(3)

3.2

Element Time Te Preceded by: Element Time Te Preceded by:

1 0.4 min - 6 0.2 min 3
2 0.7 min 1 7 0.3 min 4
3 0.5 min 1 8 0.9 min 4, 9
4 0.8 min 2 9 0.3 min 5, 6
5 1.0 min 2, 3 10 0.5 min 7, 8

With respect to the table above, determine:

(a) the total work content for the assembly (3)
(b) draw the precedence diagram (5)
TOTAL [44]