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ktra hệ thống sản xuất tích hợp

The document describes a production process with the following key details: - There are 10 automatic lathes that process parts in batches of 100 units. - The average setup time is 5 hours and operation time is 9 minutes per part. - Five operators are assigned to run one or two machines each. - The section operates one 8-hour shift per day, 5 days per week. - The production manager claims capacity is 2,000 units per week but actual output is only 1,600 units. The problem is that actual weekly production is lower than the claimed capacity. A solution would be to analyze factors like setup times, operation times, and resource allocation to identify ways to improve efficiency and increase output
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0% found this document useful (0 votes)
266 views47 pages

ktra hệ thống sản xuất tích hợp

The document describes a production process with the following key details: - There are 10 automatic lathes that process parts in batches of 100 units. - The average setup time is 5 hours and operation time is 9 minutes per part. - Five operators are assigned to run one or two machines each. - The section operates one 8-hour shift per day, 5 days per week. - The production manager claims capacity is 2,000 units per week but actual output is only 1,600 units. The problem is that actual weekly production is lower than the claimed capacity. A solution would be to analyze factors like setup times, operation times, and resource allocation to identify ways to improve efficiency and increase output
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as DOCX, PDF, TXT or read online on Scribd
You are on page 1/ 47

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1 (a) A batch of parts is produced on a semi-automated production


machine. The batch size is 200 units. Setup requires 55 min. A worker
loads and unloads the machine each cycle, which takes 0.44 min.
Machine processing time is 2.86 min/cycle, and tool handling time is
negligible. One part is produced each cycle. Determine

(a) average cycle time,

(b) time to complete the batch,

and (c) average production rate

(a) average cycle time = loading time + processing time = 0.44+2.86 =


3.3 minutes.

(b) time to complete the batch = set up time + processing time + no-
operation time

= 55 + (200*2.86) + (200*0.44) = 55 + 572 + 88 = 715 minutes = 11.91


hours.

(c) average production rate = 1/ (time to complete the batch/batch


size) = 1/ (11.91/200) = 1/0.0595 = 16.806 units/ hour

3.3 A batch production operation has a machine setup time of 3.0 hr and a processing time of
1.60 min per cycle. Two parts are produced each cycle. No tool handling time is included in the
cycle. Part handling time each cycle is 45 sec. It consists of the worker obtaining two starting
work units from a parts tray, loading them into the machine, and then after processing, unloading
the completed units and placing them into the same tray. Each tray holds 24 work units. When all
of the starting work units have been replaced with completed units, the tray of completed parts is
moved aside and a new tray of starting parts is moved into position at the machine. This irregular
work element takes 3.0 min. Batch quantity is 2,400 units. Determine (a) average cycle time, (b)
time to complete the batch, and (c) average production rate.
3.4 A flow-line mass production operation consists of eight manual workstations. Work units
are moved synchronously and automatically between stations, with a transfer time of 15 sec. The
manual processing operations performed at the eight stations take 40 sec, 52 sec, 43 sec, 48 sec,
30 sec, 57 sec, 53 sec, and 49 sec, respectively. Determine (a) cycle time 68 (b) time to process
one work unit through the eight workstations, (c) average production rate, and (d) time to produce
10,000 units.

(a) cycle time for the line

Ans - To determine the cycle time for the line,


Explanation:
we need to find the maximum time taken at any workstation.
In this case, the workstation with the longest processing time takes 57 seconds.
Therefore, the cycle time for the line is 57 seconds.

b) time to process one work unit through the eight workstations


Ans - To calculate the time to process one work unit through the eight workstations,
we add the processing time at each workstation and the transfer time between
stations.

Total processing time = 40 + 52 + 43 + 48 + 30 + 57 + 53 + 49 = 372 seconds Total


transfer time = 15 seconds * (8 - 1) = 105 seconds Time to process one work unit =
Total processing time + Total transfer time = 372 + 105 = 477

(c) average production rate

Ans - The average production rate is the reciprocal of the cycle time.
Explanation:
Average production rate: 1 / Cycle time = 1 / 57 units per second

Therefore, the average production rate is 1/57 units per second.

(d) time to produce 10,000 units.

Ans - To calculate the time to produce 10,000 units, we multiply the time to process
one work unit by the number of units.

Time to produce 10,000 units = Time to process one work unit * 10,000 = 477 *
10,000 = 4,770,000 seconds.

3.5 Average setup time on a certain production machine is 4.0 hr. Average batch size is 48 parts,
and average operation cycle time is 4.2 min. The reliability of this machine is characterized by
mean time between failures of 37 hr and a mean time to repair of 55 min. (a) If availability is
ignored, what is the average hourly production rate of the machine. (b) Taking into account the
availability of the machine, determine its average hourly production rate. (c) Suppose that
availability only applied during the actual run time of the machine and not the setup time.
Determine the average hourly production rate of the machine under this scenario

Cycle time, Tc = 4.2min = (4.2÷60) = 0.07 hr

Setup time, Tsu = 4hr

Batch size, Q = 48 units

Batch production time, Tb = ( Tsu + ( Q × Tc )) = ( 4 + ( 48 × 0.07 )) =


7.36 hr
Average production time per unit, Tp = ( Tb ÷ Q ) = ( 7.36 ÷ 48) = 0.153
hr

a.) Without considering availability

Average production rate, Rp = ( 1÷ Tp ) = ( 60 ÷ 0.153 ) = 6.52 units/hr

b.) Considering availability

MTTR = 55min = ( 55 ÷ 60 ) = 0.916 hr

MTBF = 37 hr

Availability, A = (( MTBF ÷ ( MTBF + MTTR )) × 100 ) = (( 37 ÷ ( 37 +


0.916))×100) = 97.5%

Batch production time, Tb = (( Tsu + ( Q × Tc )) × ( 1+(1 - A ))) = (( 4 +


( 48 × 0.07 )) × ( 1 + (1 - 0.975)) = 13.776 hr

Average production time per unit, Tp = ( Tb ÷ Q ) = ( 13.776 ÷ 48 ) =


0.287 hr

Average production rate, Rp = ( 1 ÷ Tp ) = ( 1 ÷ 0.287 ) = 3.48 units/hr

c.) Considering availability not in the setup time

Batch production time, Tb = ( Tsu + ( Q × Tc × ( 1+ (1 - A) ))) = ( 4 + ( 48


× 0.07 × (1+(1- 0.975))) = 7.44 hr

Average production time per unit, Tp = ( Tb ÷ Q ) = ( 10.636 ÷ 48 ) =


0.155 hr

Average production rate, Rp = ( 1 ÷ Tp ) = ( 1 ÷ 0.155 ) = 6.44 units/hr

3.6 A mass-production plant has six machines and currently operates one 8-hr shift per day, 5
days per week, 50 weeks per year. The six machines produce the same part each at a rate of 12
pc/hr. (a) Determine the annual production capacity of this plant. (b) If the plant were to operate
three 8-hr shifts per day, 7 days per week, 52 weeks per year, determine the annual percentage
increase in plant capacity?

a. 144,000

b. 336.8 %
Solution :

A.)

Annual capacity = production rate per hour × number of hours in a day


× days in a week × number of weeks in a year × number of machines =
12 × 8 ×5 × 50 ×6 = 144,000 units
Explanation:
Please refer to the solution in step.
B.)

New annual capacity = 12× 8 × 3 × 7×52 ×6 = 628,992 units

% increase in capacity = (new capacity - old capacity)/old capacity ×


100 = (628,992-144,000)/144,000 ×100 = 336.8%
Explanation:
New annual capacity = 12× 8 × 3 × 7×52 ×6 = 628,992 units

3.7 One million units of a certain product are to be manufactured annually on dedicated production
machines that run 16 hr per day, 5 days per week, 50 weeks per year. (a) If the cycle time of a machine to
produce one part is 1.2 min, how many of the dedicated machines will be required to keep up with
demand? Assume that availability and utilization are 100%, and that setup time can be neglected. (b)
Solve part (a) except that availability = 90%
3.8 A job shop has four machines and operates 40 hr/wk. During the most recent week, machine
1 processed part A for 25 hr at a production rate of 10 pc/hr, and part B for 12 hr at a rate of 7
pc/hr. Machine 2 processed part C for 37 hr at a rate of 14 pc/hr, and was idle 3 hr. Machine 3
processed part D for 15 hr at a rate of 20 pc/hr, and part E for 25 hr at a rate of 15 pc/hr. Machine
4 processed part F for 13 hr at a rate of 9 pc/hr, part G for 12 hr at a rate of 18 pc/hr, and was idle
the rest of the week. Determine (a) weekly production output of the shop and (b) average
utilization of equipment.

(a) weekly production output of the shop

Machine 1 : Part A

25 hours * 10parts = 250 parts

Part B

12hours * 7 parts = 84 parts

Machine 2 : Part C
37 hours * 14 parts = 518 parts

Machine 3 : Part D

15 hours * 20parts = 300 parts

Part E

25 hours * 15 parts = 375 parts

Machine 4 : Part F

13 hours * 9 parts = 117 parts

Part G

12 hours * 18parts = 216 parts

Total weekly productions =1860 parts


3.10 There are 10 machines in the automatic lathe section of a certain machine shop. The setup
time on an automatic lathe averages 5 hr. Average batch size for parts processed through the
section is 100. Average operation time = 9.0 min. Under shop rules, an operator can be assigned
to run one or two machines. Accordingly, there are five operators in the section for the 10 lathes.
In addition to the lathe operators, there are two setup workers who perform only machine setups.
These setup workers are busy the full shift. The section runs one 8-hr shift per day, 5 days per
week. Scrap losses are negligible and availability = 100%. The production control manager
claims that the capacity of the section should be 2,000 parts per week. However, the actual output
averages only 1,600 units per week. What is the problem? Recommend a solution.

The capacity of the automatic lathe section in the machine shop can
be determined using several factors provided in the scenario:
1. Number of Machines: There are 10 automatic lathes in the section.
2. Setup Time: The average setup time on an automatic lathe is 5
hours.
3. Batch Size: The average batch size for parts processed through the
section is 100.
4. Average Operation Time: The average operation time per part is 9.0
minutes.
5. Operator Assignment: An operator can be assigned to run one or two
machines, and there are five operators in the section for the 10 lathes.
6. Setup Workers: Two setup workers are available who perform
machine setups and are busy for the full shift.
7. Shift Schedule: The section runs one 8-hour shift per day, 5 days per
week.
8. Scrap Losses: Negligible scrap losses, and availability is 100%.

Explanation:
Capacity calculation is a fundamental concept in operations
management that quantifies a system's ability to produce goods or
deliver services within a specified time frame. It plays a critical role in
assessing and optimizing the efficiency of production processes.

Capacity calculation takes into account several key factors. Firstly, it


considers the available resources, such as the number of machines,
equipment, or personnel, that can be utilized during a given period,
typically measured in hours or shifts.

Secondly, it factors in production or processing times, including setup


times, operation times, and any downtime. These times help determine
how much productive work can be accomplished during the available
time.

Lastly, capacity calculation considers the production rate or


throughput, which is the rate at which products or services are
delivered. It's often measured in units per hour or other relevant units
of output.

The goal of capacity calculation is to ensure that a system is operating


optimally without overloading or underutilizing resources. It aids in
making informed decisions about resource allocation, staffing, and
production scheduling. By accurately assessing capacity, businesses
can meet customer demands efficiently, reduce lead times, and
enhance overall operational performance. Capacity calculations are
essential in industries ranging from manufacturing to service
operations, where efficient resource utilization is a key to success.
3.12 Suppose the part in the previous problem is made in very large quantities on a production
line in which an automated work handling system is used to transfer parts between machines.
Transfer time between stations is 15 sec. Total time required to set up the entire line is 150 hr.
Assume that the operation times at the individual machines remain the same as in the previous
problem. Determine (a) manufacturing lead time for a part coming off the line, (b) production
rate for operation 3, (c) theoretical production rate for the entire production line. (d) How long
would it take to produce 10,000 parts after the setup has been completed?
3.16 The average part produced in a certain batch manufacturing plant must be processed
sequentially through an average of eight operations. Twenty new batches of parts are launched
each week. Average operation time is 6 min, average setup time is 5 hr, average batch size is 25
parts, and average nonoperation time per batch is 10 hr per machine. There are 18 machines in
the plant. Any machine can be set up for any type of batch processed in the plant. The plant
operates 75 production hr/wk. Determine (a) manufacturing lead time for an average part, (b)
plant capacity if all machines could be operated at 100% utilization, (c) plant utilization, and (d)
work-in-process (number of parts-in-process). (e) How would you expect the nonoperation time
to be affected by plant utilization?
7 On average,
3.24 A customer has requested a quotation for a machining job consisting of 80 parts. The starting work
part is a casting that will cost $17.00 per casting. The average production time of the job is 13.80 min on
an automatic machine whose equipment cost rate is $66.00/hr. This rate does not include any overhead
costs. Tooling cost is $0.35 per part. The factory overhead rate is 128% and the corporate overhead rate
is 230%. These rates are applied only to time and tooling costs, not starting material costs. The company
uses a 15% markup on total cost for its price quotes. What is the quoted price for this job?

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