Review: Manufacturing Operation

A factory produces cardboard boxes. The production sequence consists of three operations: (1) cutting, (2)
indenting, and (3) printing. There are three machines in the factory, one for each operation. The machines are
100% reliable and operate as follows when operating at 100% utilization: (1) In cutting, large rolls of cardboard
are fed into the cutting machine and cut into blanks. Each large roll contains enough material for 4,000 blanks.
Production cycle time = 0.03 minute/blank during a production run, but it takes 35 minutes to change rolls
between runs. (2) In indenting, indentation lines are pressed into the blanks to allow the blanks to later be bent
into boxes. The blanks from the previous cutting operation are divided and consolidated into batches whose
starting quantity = 2,000 blanks. Indenting is performed at 4.5 minutes per 100 blanks. Time to change dies on
the indentation machine = 30 min. (3) In printing, the indented blanks are printed with labels for a particular
customer. The blanks from the previous indenting operation are divided and consolidated into batches whose
starting quantity = 1,000 blanks. Printing cycle rate = 30 blanks/min. Between batches, changeover of the
printing plates is required, which takes 20 minutes. In-process inventory is allowed to build up between
machines 1 and 2, and between machines 2 and 3, so that the machines can operate independently as much as
possible. Based on this data and information, determine the maximum possible output of this factory during a
40-hour week, in completed blanks/week (completed blanks have been cut, indented, and printed)? Assume
steady state operation, not startup.

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Solution
Solution: Determine maximum production rate Rp for each of the three operations:
Operation (1) - cutting: Tb = 35 min. + 4000 pc(0.03 min/pc) = 35 + 120 = 155 min./batch
Rp = = 1548.4 pc/hr
Operation (2) - indenting: Tb = 30 min. + 2000 pc(4.5/100 min./pc) = 30 + 90 = 120
min./batch
Rp = = 1000 pc/hr
Operation (3) - printing: Tb = 20 min. + = 20 + 33.33 = 53.33 min./batch
Rp = = 1125 pc/hr
Bottleneck process is operation (2). Weekly output = (40 hr/wk)(1000 pc/hr) = 40,000
blanks/wk.

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Single Station Automated Cell

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Lesson Objectives
Understand the concept of single cells station and its application
Evaluate performance of Single station cells

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Classification of Manufacturing system
M( Manual) A (Automated) H (Hybrid)
Type
I
In Out In Out
Man
Auto

Single Station Manned cell Single Station Auto cell

Type
II
Man Man

Man
Auto Auto Auto Out
In Out
In Out
Man Man Auto Auto
Auto Auto
In

Multi station hybrid with variable

Type Multi Station manual with variable routing Multi Station auto with variable routing routing
III
Auto Man Auto Man
In Out Auto Auto Auto
Man Man Man Man Auto In
Out
In Out

Multi Station manual with serial ops Multi Station auto with serial ops Multi Station hybrid with serial ops
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 Category of Single Manufacturing Cells

Type I M (Manual) A (Automated)

In Out In Out
Man Auto

Reason for -Requires shortest amount of -Reduced labor cost

implementation time to implement -Higher production rate,
-Least capital investment therefore lower cost per unit for
-Lowest cost per unit for low higher volume
volume - As a training ground for future

-Flexible (easy change over) implementation of integrated

- n=1, w >1 automation
- Manning level (M<1)

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Key Enablers for Automated machine
Automation is defined as capability of a machine to perform
operation unattended for longer that one machine cycle
Automation is achieved through:
◦ Programmed cycle- Machine able to perform the cycle automatically
◦ Availability of storage subsystem for raw material and finished product.
◦ Automatic raw material/product from machine to storage subsystem
◦ Communication to worker for periodic attention-ie through signal light
◦ Build in safety features
◦ To the machine itself
◦ To the workpart
◦ To the worker
◦ Work ID subsystem- to differentiate between different work units.
◦ Auto program selection based on parts being transferred
◦ Quick setup or change over.
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Parts storage subsystem and automatic part transfer
A prerequisite for a single station automated cell.
If part storage has a capacity of np, theoretically the cell can run
unattended for :
◦ UT=npTc where UT is unattended time

In actuality, UT is less than theoretical due to time needed for

loading/unloading at the storage subsystem
Typical storage capacity consideration to optimize UT:
◦ Fixed time interval so that worker can tend to multiple stations
◦ Timed such that the loading/unloading can be done between tool
change
◦ Over change of shift
◦ Overnight operation (no worker)

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 Storage Capacity
 Storage capacity of one No part storage One part storage
part > Machine is idle during >machine is utilized
 Type I M mfg system loading/unloading during loading unloading
where worker must be
in attendance full time >Cycle time:  Cycle time:
 While the machine is Tc = Tm + Ts Tc = max {Tm,Ts} + Tr
Tm = machine processing time Tm = machine processing time
processing, the worker
Ts = Worker service time Ts = Worker service time
will be doing the next Tr = Repositioning time
part loading and
unloading the finished
part.
 Comparison with no
part storage:

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 Storage Capacity
Storage capacity of greater than one part
◦ Greatly improve the unattended operation time

Examples:
◦ CNC automated pallet changer
◦ Sheet metal stamping-starting sheet coil whose length is enough for
thousand of stamped parts.
◦ Plastic injection molding-plastic pallets above heating barrel which is
enough for hundreds of molded parts
◦ Buffer conveyor system for discreet electronic components

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 Application of single station manned cells
(Type IM)
A CNC machining center where a worker is required to at the
end of each program execution to load and unload parts
A semi-auto plastic injection molding
◦ Worker needed to remove molding, runner system
Electronic assembly where a worker is needed to place
components to printed circuit board
A manual stamping press where a worker is needed to place a
‘blanks’ onto the die for stamping

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 Application of single station auto cells
(Type I A)
A CNC machining center with automatic pallet changer on
carousel. A worker will remove the finished product from
carousel and load starting work parts. Loading and unloading
is done while the machine is operating.
A plastic injection molding with mechanical arm to remove
molding and runner system.
◦ Finished part are collected in tote box beneath the mold
◦ Worker must periodically exchange the tote box and resupply molding
compound
A stamping press that punches and formed small sheet parts
from a long coil

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 Analysis of Single Station system
Analysis required to determine:-
◦ Number of single stations needed to satisfy production requirement
◦ Number of machine to assign to a worker

Number of Workstation required:-

◦ Determine the total workload that must be accomplished during a given period (week,
month)
For single product For multiple products

WL  QT c WL   QjTcj
j
WL- Workload Hr of work/week WL- Workload Hr of work/week
Q- Qty to be produced (pc/week) Qj- Qty to be produced for product j
Tc –Cycle time (Hr/Pc) Tcj –Cycle time for product j
◦ Divide the workload by the by the number of hours available on the workstation for the
same period.
WL
n WL – Total workload
AT- Total available time at the station (Hr/week)
AT
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Analysis of Single Station system
Other non-ideal factors need to be included in the analysis
◦ Setup time in batch production as during setup, the machine is not
producing, therefore reducing the available time (AT)
◦ Availability(A) – Reliability of equipment that reduces overall
production time (due to downtime)
◦ Utilization (U) –Not fully utilize due to scheduling problem or non-
linear material flow
AT = T A U Where T is actual clock time for the period
◦ Worker efficiency (Ew)- Depending on worker’s mood that translates
into high/low performance
◦ Defect rate (q)– Output might not be 100% good.
◦ Incorporating worker efficiency and defect rate, the total WL will be:

QT c
WL 
Ew(1  q)
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 Example
A stamping plant must be designed to supply an automotive
engine plant with sheet metal stampings. The plant will
operate one 8-hour shift for 250 days per year and must
produce 15,000,000 good quality stampings annually. Batch
size = 10,000 good stampings produced per batch. Scrap rate
= 5%. On average it takes 3.0 seconds to produce each
stamping when the presses are running. Before each batch,
the press must be set up, and it takes 4 hours to accomplish
each setup. Presses are 90% reliable during production and
100% reliable during setup. How many stamping presses will
be required to accomplish the specified production

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Solution
Solution: Production: WL = = 13,157.9 hr/yr
AT = 250(8)(0.90) = 1800 hr/yr per press
Setup: number batches/yr = = 1500 batches = 1500 setups.
WL = 1500(4) = 6000 hr/yr
AT = 250(8) = 2000 hr/yr per press.
n = = 7.31 + 3.0 = 10.31 or 11 presses

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 Machine Cluster
Definition: Collection of two or more machine producing parts or products with
identical cycle time and is serviced by one worker
Conditions that must be satisfied
◦ Semi-automatic machine cycle is long relative to service portion
◦ Semi-automatic machine cycle time is the same for all machines
◦ Machines are located in close proximity to the worker
◦ Work rule for the plant permit worker to service more than one machine

Consider a cluster of single workstations, all producing same parts and operating at
the same machine cycle time
◦ Tc = T m + Ts
Tc – Total machine cycle time
◦ Time for worker to service the machines= Ts + Tr Tm – Machine cycle time
(Tm  Ts ) Ts – service time
For a perfectly balanced systems
n Tr – Repositioning time
◦ n(Ts + Tr)=Tm + Ts or (Ts  Tr ) n – no of machine/worker
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Example
A worker is currently responsible for tending two machines in a machine
cluster. The service time per machine is 0.35 min and the time to walk
between machines is 0.15 min. The machine automatic cycle time is
1.90 min. If the worker's hourly rate = $15/hr and the hourly rate for
each machine = $20/hr, determine (a) the current hourly rate for the
cluster, and (b) the current cost per unit of product, given that two units
are produced by each machine during each machine cycle. (c) What is
the % idle time of the worker? (d) What is the optimum number of
machines that should be used in the machine cluster?

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Backup

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Alternative design for CNC part storage

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Stamping machine with coil

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