BEKC 4883

ADVANCE MANUFACTURING SYSTEM (2010/2011)

NAME : ANUAR BIN MOHAMED KASSIM COURSE : 4BEKM

TUTORIAL 2 (SCHEME)

1.

What is manufacturing?
Answer: Two definitions are given in the text, one technological and the other economic. The technological definition is the following: Manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products; manufacturing also includes the joining of multiple parts to make assembled products. The economic definition is the following: Manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations.

2.

What is the difference between a processing operation and an assembly operation?
Answer: A processing operation transforms a work material from one state of completion to a more advanced state that is closer to the final desired part or product. It adds value by changing the geometry, properties, or appearance of the starting material. An assembly operation joins two or more components to create a new entity, called an assembly, subassembly, or some other term that refers to the joining process.

3.

What is the difference between hard product variety and soft product variety?
Answer: Hard product variety is when the products differ substantially. In an assembled product, hard variety is characterized by a low proportion of common parts among the products; in many cases, there are no common parts. Soft product variety is when there are only small differences between products. There is a high proportion of common parts among assembled products whose variety is soft.

4.

What is lean production?
Answer: The definition given in the text is the following: Lean production means operating the factory with the minimum possible resources and yet maximizing the amount of work that is accomplished with these resources. Lean production also implies completing the products in the minimum possible time and achieving a very high level of quality, so that the customer is completely satisfied. In short, lean production means doing more with less, and doing it better.

5.

In lean production, what is just-in-time delivery of parts?
Answer: As defined in the text, just-in-time delivery of parts refers to the manner in which parts are moved through the production system when a sequence of manufacturing operations is required to make them. In the ideal just-in-time system, each part is delivered to the downstream workstation immediately before that part is needed at the station.

6.

In lean production, what does continuous improvement mean, and how is it usually accomplished?
Answer: Continuous improvement involves an unending search for ways to make improvements in products and manufacturing operations. It is usually accomplished by worker teams who cooperate to develop solutions to production and quality problems.

000 hr/yr.000. and (c) how many workers will be required in the plant. and (c) how many workers will be required in the plant.000 hr/yr.0 minute (includes an allowance for setup time and part handling). Each product will be assembled of 600 components. and the factory operates one shift (2000 hr/yr). All processing operations are performed at work cells that each includes a production machine and a human worker.000 products/yr Number of final assembly operations = 100. (includes an allowance for setup time and part handling).5 min. Each product will be assembled of 400 components. All processing operations are performed at workstations.000hr / yr = 1000 workers. All processing of parts will be accomplished in one factory. determine (a) how many production operations. The new product line will include 100 different models. and each processing step takes 30 sec. Total assembly operation time = (100 x 103 asby ops)(3 hr/product) = 300.000./(60 min./hr)) = 2.0 hours to assemble.7. The ABC Company is planning a new product line and will build a new plant to manufacture the parts for a new product line.000. The XYZ 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. At 2000 hours/yr per worker.000 asby ops/yr Number of processing operations nof = PQnpno = 100(1000)(600)(10) = 600. Annual production of each model is expected to be 1000 units. (b) how much floorspace. and the factory operates one shift (2000 hr/yr). Solution: (a) Qf = PQ = 100(1000) = 100.000.000 operations in the factory per year. Each final unit of product takes 3. (a) nof = PQnpno = 50(1000)(400)(6) = 120. All processing of parts and assembly of products will be accomplished in one factory. Products are assembled on single workstations consisting of two workers each. (c) Total operation time = (120 x 106 ops)(1min.000 proc ops/yr (c) Total processing operation time = (600 x 106 ops)(0. determine: (a) how many production operations. If each workstation requires a floor space of 250 ft2. and each processing step takes 1. Solution: This problem neglects the effect of assembly time. If each work cell and each workstation require 200 ft2.300. The product line will include 50 different models. (b) how much floorspace./(60 min./hr)) = 5.000.000 ft2 8. Total floorspace = (1000 stations)(250 ft2/station) = 250. There are an average of 6 processing steps required to produce each component.000 hr/yr Total processing and assembly time = 5. w = 2. There are an average of 10 processing steps required to produce each component. 2000hr / wor ker (b) Number of workstations n = w = 1000. Annual production of each model is expected to be 1000 units.000 hr/yr . each of which includes a production machine and a human worker.

At 2000 hours/yr per worker.000hr / yr = 2650 workers. n = w/2 = 150/2 = 75 workstations.000 ft2 . With 2 workers per stations for assembly. Total floor space A = (2575 stations)(200 ft2/station) = 515. w = 5. n = w = 2500 = 2500 workstations. 2000hr / wor ker (b) With 1 worker per workstation for processing operations.300.