IE 5403 FACILITIES DESIGN AND PLANNING PRACTICE #5 (06.11 ...

IE 5403FACILITIES DESIGN AND PLANNINGPRACTICE #5(06.11.2012)1) Answer the following capacity questionsMachine M1 M2 M3 M4Design Capacity 100 150 80 90Effective Capacity 70 100 65 60a) When these machines are connected serially and produce 50 units actual outputa. What is the system efficiency?b. What is the system utilization?c. What is the idle capacity in the produced unit?b) When M1//M2 working parallel and M3//M4 working parallel are connected seriallya. Compute the actual output of this new system when the percentage idlecapacity stays the same as that in the previous serial system.b. Compute the efficiency and the utilization of the system.2) A plastic injection molding plant will be built to produce 6 million molded parts per year.The plant will run 8-hour shifts per day, five days per week, and 50 weeks per year. Forplanning purposes, the average batch size=6000 moldings, average changeover time betweenbatches=6 hrs, and average molding cycle time per part=30 sec. Assume scrap rate=2%. Howmany molding machines are required in the new plant?3) The processing time of one product is changed according to the performance of operatorsin a manufacturing line. Four observed operators 1, 2, 3 and 4 produce the same productwith the processing time of 10 min/unit, 20 min/unit, 15 min/unit and 30 min/unitrespectively. Find an appropriate average processing time to be used in computations anddetermine required number of machines so that this manufacturing line can produce2400 good products within available time of 480 min. under the defective rate of 0.03and efficiency of 90%.

4) Two components (T1 and X1) are assembled to make model TX1. Actual demand of modelTX1 is 600 units/year. Two units of T1 and three units of X1 are required to make oneunit of model.a. Operation sequences and processing times of two components (T1 and X1) are givenin the following table. If available time in a year equals to 1200 hours, determine thenumber of machines for milling and turning operations with respect to process layoutand product layout.ComponentOperationProcess time,min/unitDefective rate,%T1 Milling 15 ---Turning 25 ---Inspection disregard 5Assembly 10 ---Inspection disregard 4X1 Milling 25 ---Inspection disregard 8Assembly 10 ---Inspection disregard 4b. Determine the number of workers for assembly operation with respect to process andproduct layout. (hint: same principle of determining number of machines can beused)c. Each turning and milling machine can be purchased at $50,000 and $75,000respectively. Unit operating costs are $25/unit for turning operation and $15/unit formilling operation. Products (TX1) can be sold to the customer for $250 per unit.Determine the number of years to pay off purchasing costs of machines.