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Assignment 1

Flexible Manufacturing Process


1. GT cell will machine the components for a family of parts. The parts come in several different
sizes and the cell will be designed to quickly change over from one size to the next. This will be
accomplished using fast-change fixtures and downloading the part programs from the plant
computer to the CNC machines in the cell. The parts are rotational type, and so the cell must be
able to perform turning, boring, facing, drilling, and cylindrical grinding operations.
Accordingly, there will be several machine tools in the cell, of types and numbers to be specified
by the designer. To transfer parts between machines in the cell, the designer may elect to use a
belt or similar conveyor system. Any conveyor equipment of this type will be 0.4 m. wide. The
arrangement of the various pieces of equipment in the cell is the principal problem to be
considered. The raw workparts will be delivered into the machine cell on a belt conveyor. The
finished parts must be deposited onto a conveyor that delivers them to the assembly department.
The input and output conveyors are 0.4 m wide, and the designer must specify where they enter
and exit the cell. The parts are currently machined by conventional methods in a process-type
layout. In the current production method, there are seven machines involved but two of the
machines are duplicates. "From-to" data have been collected for the jobs that are relevant to this
problem.

The from-to data indicate the number of workparts moved between machines during a typical 40
hour week. The data refer to the parts considered in the case. The two categories "parts in" and parts
out" indicate parts entering and exiting the seven machine group. A total of 400 parts on average are
processed through the seven machines each week. However, as indicated by the data, not all 400 parts
are processed by every machine. Machines 4 and 5 are identical and assignment of parts to these
machines is arbitrary. Average production rate capacity on each of the machines for the particular
distribution of this parts family is given in the table below. Also given are the floor space dimensions of
each machine in meters. Assume that all loading and unloading operations take place in the center of the
machine.
Operation 6 is currently a manual inspection operation. It is anticipated that this manual station will
be replaced by a coordinate measuring machine (CMM). This automated inspection machine will triple
throughput rate to 15 parts per hour from 5 parts per hour for the manual method. The floor space
dimensions of the CMM are 2.0 m x 1.6 m. All other machines currently listed are to be candidates for
inclusion in the new machine cell.
Find:- (a) Analyze the problem and determine the most appropriate sequence of machines in the
cell using the data contained in the From-To chart. (b) Construct the network diagram for the cell,
showing where and how many parts enter and exit the cell. (c) Determine the utilization and production
capacity of the machines in the cell as you have designed it. (d) Prepare a layout (top view) drawing of
the GT cell, showing the machines, the robot(s), and any other pieces of equipment in the cell. (e) Write
a one-page (or less) description of the cell, explaining the basis of your design and why the cell is
arranged as it is.

2. A warehouse consists of five aisles of racks (racks on both sides of each aisle) and a loading
dock. The rack system is four levels high. Forklift trucks are used to transport loads between the
loading dock and the storage compartments of the rack system in each aisle. The trucks move at an
average speed = 140 m/min (loaded) and 180 m/min (empty). Load handling time (loading plus
unloading) per delivery totals 1.0 min per storage/retrieval delivery on average, and the anticipated
traffic factor = 0.90. Worker efficiency = 100% and vehicle reliability (availability) = 96%. The
average distance between the loading dock and the centers of aisles 1 through 5 are 200 m, 300 m, 400
m, 500 m, and 600 m, respectively. These values are to be used to compute travel times. The required
rate of storage/retrieval deliveries is 100 per hour, distributed evenly among the five aisles, and the
trucks perform either storage or retrieval deliveries, but not both in one delivery cycle. Determine the
number of forklift trucks required to achieve the 100 deliveries per hour.

3. What are the typical objectives when implementing cellular manufacturing? Explain in Brif.
4. What are the three methods for solving the problem of grouping parts into part families? Explain
In brief.

Solve the Assignment in File Pages only. Used both side line pages.

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