2011-2012 Material Handling Student Design Competition Case ...

2011-2012 Material Handling Student Design 

Competition Case – Issues Tracking Document 

Prepared for CICMHE, 

The College Industry Council on Material Handling Education 

November 6, 2011 

Version 1.0 

This document is for the exclusive academic usage of the 2011-2012 Material Handling Student 

Design Competition.

Table of Contents 

I. PURPOSE OF THAT DOCUMENT ...................................................................................................... 3 

1. ISSUES ...................................................................................................................................................... 4 

QUESTION/ISSUE #1: SHEET "RESOURCE TYPE - CAPABILITY" .................................................................... 4 







QUESTION/ISSUE #8: SHEET "RES. TYPE SPEC. RATEBYHR" ....................................................................... 5 

QUESTION/ISSUE #9: SHEET "RES. TYPE SPEC. RATEBYHR" ....................................................................... 5 

QUESTION/ISSUE #10: SHEET "HEADTYPE (SETUP TABLE)" ........................................................................ 5 

QUESTION/ISSUE #11: PAGE 6 OF THE PACKET, POINT #17 ........................................................................... 5 

QUESTION/ISSUE #12: SHEET "RESOURCE TYPE - CAPABILITY" .................................................................. 6 

QUESTION/ISSUE #13: SHEET "RES. TYPE SPEC. RATEBYHR" ..................................................................... 6 

QUESTION/ISSUE #14: PAGE 6 OF THE PACKET, POINT #27 ........................................................................... 6 

Reproduction and distribution without 

prior consent prohibited. 

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© 2011 West Monroe Partners, LLC 

Proprietary and confidential

I. PURPOSE OF THAT DOCUMENT 

This document is used to track questions and answers and comments about issues raised by the 

students. 



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1. ISSUES 

Question/Issue #1: sheet "Resource Type - Capability" 

For Manufacturing process "Coating": Machine_119, Machine_120 and Machine_121 are 

duplicated. 

Answer: The new version of the excel document fixes that error. 


For Manufacturing process "Electro - Zinc (Yellow)": Machine_119, Machine_120 and 

Machine_121 are duplicated. 



For Manufacturing process "Oil Quench": Machine_61, Machine_62, Machine_63 and 

Machine_64 are duplicated. 



For Manufacturing process "Quality Test": Machine_124 is duplicated. 



For Manufacturing process "Annealing": Machine_70 is duplicated. 



For Manufacturing process "Galvanization": Machine_119, Machine_120 and Machine_121 are 

duplicated. 




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Machines 28, 65, 66, 72, 81, and 91-118 are missing entirely. 

Answer: Yes... In that case, it is the responsibility of the design team to decide what to do with 

that piece of information. If a machine is not capable to process any manufacturing process... it 

means? 

Question/Issue #8: sheet "Res. Type Spec. RateByHr" 

There are no rates for machines 28, 65, 66, 81, and 91-126. For machines 28,65,66,81, 

91-118, the answer is simple (see issue #7). 

Machine_126 is for the process "storage". In that case, there is no processing time at 

all... 


Values are duplicated for some combinations "Resource Type - Part - Op Id". 

Answer: We have removed the duplicates. The new version of the excel document fixes that 

error. All processing times have been reviewed for the resource specific rates per hour and for 

the operation batch times. 

Question/Issue #10: sheet "HeadType (Setup Table)" 

"We don't understand how it could take up to 12 hrs to change a head on a machine" 

Answer: The setup means to change all components of the die. It forces the operator to remove 

the material, to uninstall the dies, to install the new dies, to calibrate the dies and adjust the 

mechanical tolerances. 

Question/Issue #11: page 6 of the packet, point #17 

In the forging department (cold and hot forging), the following setup rules must be considered: 

a. Change of Head Type: sequence dependent setup (see table HeadType (Setup 

Table) in the excel document) 

b. Change of Grade: setup time of 30 minutes 

c. Change of Length Type: setup time of 45 minutes 

Answer: 

Setup Time = Max (setup a., setup b., setup c.). Setups are concurrent... 



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Answer: For Manufacturing process Threading: Machine_82 is duplicated. The new version of the 

excel document fixes that error. 


Some combination "part - operation" should not appear in that list and should appear only in the 

sheet "Operation Batch Time". 

Answer: The new version of the excel document fixes that error. See issue #9. 

Question/Issue #14: page 6 of the packet, point #27 

"Cost to build the plant can be estimated at $125 per square foot." vs Table on page 8. Are the 

costs on the table the basis for the average, or are they in addition to it? Do we need to address 

the individual costs, or should we assume that the totals are sufficient? 

Answer: do not consider point 27 anymore. Consider the table of point 31 



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