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PRDT03I05 Plant Layout and Material Handling Assignment Grading: 15% Submission deadline: Monday, 31/10/2011

Problem # 1 1) 2) 3)

(3%)

List potential goals of manufacturing facilities design and material handling. Mention the types of manufacturing facilities design projects. Lean manufacturing is concerned with eliminating wastes. List 8 types of these wastes.

Problem # 2

(1%)

For a workshop producing tables as shown in Fig. 2-1 with the given product structure tree, develop an indented bill of material for the table, taking into consideration that the workshop purchase the readymade legs and fabricate the boards and panels in-house.

Fig. 2-1 Table

Problem # 3

(1%)

Compare between Process-oriented layouts and Product-oriented layouts and draw a schematic sketch for each.

Problem # 4

(1%)

Make the conversions and complete the table. Standard Minutes 0.05 0.01420 0.95 8.2 Standard Hours Units per Hour

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Problem # 5

(2%)

For a certain company having the 3 products X, Y and Z, the following is the operation sequence for each product: X: ACHGEFI Y: ACEGI Z: AHFBDGI Where A is the receiving department, I is the shipping department, B, C, D, E, F, G and H are processing departments. 1) A For the following layout draw the Multicolumn process chart for the three products. B C D E F G H I

2)

Taking into consideration the quantity produced per day and that the three products have the same weight of 1 Kg. and reducing backtracking, improve the flow using the From-To chart by changing the arrangement of the departments. An efficiency above 40% is required.
Quantity produced per day 300 100 200

Part X Y Z

Problem # 6

(2.5%)

An electric appliances company has a repair centre with the following departments: 123456789Parking area Clients reception Spare parts store Administration Customer service (where clients submit and receive appliances, and pay the bill) Repair workshop Quality Control Management Warehouse for electric appliances (repaired and to be repaired)

In an attempt to find an efficient arrangement of the departments of the repair centre, carry out the following: 1) 2) 3) 4) The activity relationship diagram The worksheet The dimensionless block diagram The flow analysis

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Problem # 7

(2.5%)

For a readymade garments company, Fig. 7-1 is showing a typical structure of the organization. The stages of the production are shown in the sequence of the product manufacturing (1 to 7).

Fig. 7-1 Organization of a Clothing Manufacturing Company Adapted from the source: Hannelore Eberle, Hermann Hermeling, Marianne Hornberger, Dieter Menzer and nd Werner Ring, Clothing Technology (2 edition), EUROPA-LEHRMITTEL, 1999.

An order of 10,000 T-shirts is to be accomplished at stage 4 in 10 working days and a sewing line is to be composed out of three types of machines as according to the operations sequence shown in the table below. The operations sequence on the sewing line is as follows:
Operation 1. Stitching the shoulder seams 2. Attaching the neckband 3. Forming the sleeves and stitching 4. Assembling the sleeves 5. Assembling front and back 6.Stitching the hem 7.Label stitching Machine Overedge Overedge Flat seam Overedge Overedge Flat seam Lockstitch Time required in seconds 21 23 32 29 43 21 9

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For the order mentioned, compose the line for stage 4 that achieve the order in 10 working days; Determine the number of machines required out of each type and compose the line Conduct the line balancing Calculate the line efficiency

Taking into account the following: The company is working 5 days / week and one 8 hours shift, the material is ready for stage 4 and the production of the order should take 10 working days at the stage 4. For the sewing line (stage 4), 10% allowance should be added. This stage has 85 percent performance. Expected percentage of rejected pieces due to quality is 1% for each of the operations 3 and 6. Each machine in the line should do only one type of operation.

Hint: use the decimal minute

The following is only informative:

Fig. 7-2 How a T-shirt is made Source: http://www.madehow.com/Volume-2/T-Shirt.html

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Fig. 7-3 Machine types and applications Source: Hannelore Eberle, Hermann Hermeling, Marianne Hornberger, Dieter Menzer and Werner Ring, nd Clothing Technology (2 edition), EUROPA-LEHRMITTEL, 1999.

Fig. 7-4 A Typical layout for the production department Source: Hannelore Eberle, Hermann Hermeling, Marianne Hornberger, Dieter Menzer and Werner Ring, nd Clothing Technology (2 edition), EUROPA-LEHRMITTEL, 1999.

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Problem # 8

(2%)

A company produces screwdrivers represented in Fig. 8-1. The main operations sequence for the tool is shown in Fig. 8-2 and for the handle in Fig. 8-3. The tool and the handle are assembled by a hydraulic press. Use this information to develop the Operations chart for this screwdriver.

Fig. 8-1 The Screwdriver Source: http://www.madehow.com/Volume-1/Screwdriver.html

Fig. 8-2 Main operations sequence for fabrication of the tool Source: http://www.madehow.com/Volume-1/Screwdriver.html

Fig. 8-3 Main operations sequence for fabrication of the handle Source: http://www.madehow.com/Volume-1/Screwdriver.html

The following is only Informative: For more information you can visit the link: http://www.madehow.com/Volume-1/Screwdriver.html