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

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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. Question/Issue #2: sheet "Resource Type - Capability" For Manufacturing process "Electro - Zinc (Yellow)": Machine_119, Machine_120 and Machine_121 are duplicated. Answer: The new version of the excel document fixes that error. Question/Issue #3: sheet "Resource Type - Capability" For Manufacturing process "Oil Quench": Machine_61, Machine_62, Machine_63 and Machine_64 are duplicated. Answer: The new version of the excel document fixes that error. Question/Issue #4: sheet "Resource Type - Capability" For Manufacturing process "Quality Test": Machine_124 is duplicated. Answer: The new version of the excel document fixes that error. Question/Issue #5: sheet "Resource Type - Capability" For Manufacturing process "Annealing": Machine_70 is duplicated. Answer: The new version of the excel document fixes that error. Question/Issue #6: sheet "Resource Type - Capability" For Manufacturing process "Galvanization": Machine_119, Machine_120 and Machine_121 are duplicated. Answer: The new version of the excel document fixes that error. Reproduction and distribution without prior consent prohibited. 4 © <strong>2011</strong> West Monroe Partners, LLC Proprietary and confidential
Question/Issue #7: sheet "Resource Type - Capability" 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... Question/Issue #9: sheet "Res. Type Spec. RateByHr" 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... Reproduction and distribution without prior consent prohibited. 5 © <strong>2011</strong> West Monroe Partners, LLC Proprietary and confidential
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