What are some of the realities mentioned at the beginning of the chapter
that modern manufacturing enterprises must cope with? (1) globalization,
(2) international outsourcing, (3) local outsourcing, (4) contract manufacturing -Production systems can be divided into two categories or levels. Name and briefly define the two levels. (1) facilities, which consist of the factory, the equipment in the factory, and the way the equipment is organized; and (2) manufacturing support systems, which is the set of procedures used by the company to manage production and to solve the technical and logistics problems encountered in ordering materials, moving the work through the factory, and ensuring that products meet quality standards. - Manufacturing systems are divided into three categories, according to worker participation. Name the three categories. (1) manual work systems, (2) worker-machine systems, and (3) automated systems. - Three basic types of automation are defined in the text. What is fixed automation and what are some of its features? Fixed automation is a system in which the sequence of processing (or assembly) operations is fixed by the equipment configuration. Each operation in the sequence is usually simple, but the integration and coordination of many such operations into one piece of equipment makes the system complex. Typical features of fixed automation are (1) high initial investment for custom-engineered equipment, (2) high production rates, and (3) relatively inflexible in accommodating product variety. -What is programmable automation and what are some of its features? The operation sequence is controlled by a program, which is a set of instructions coded so that they can be read and interpreted by the system. Some of the features of programmable automation are (1) high investment in general purpose equipment, (2) lost production time due to changeovers of physical setup and reprogramming, (3) lower production rates than fixed automation, (4) flexibility to deal with variations and changes in product configuration, and (5) most suitable for batch production. -What is flexible automation and what are some of its features? Flexible automation is an extension of programmable automation. A flexible automated system is capable of producing a variety of parts (or products) with virtually no time lost for changeovers from one part style to the next. There is no lost production time while reprogramming the system and altering the physical setup. Accordingly, the system can produce various mixes and schedules of parts or products instead of requiring that they be made in batches. The features of flexible automation are (1) high investment for a custom-engineered system, (2) continuous production of variable mixtures of products, (3) medium production rates, and (4) flexibility to deal with product design variations -Identify three situations in which manual labor is preferred over automation. (1) The task is technologically too difficult to automate. (2) Short product life cycle. (3) Customized product. - What is the USA Principle? What does each of the letters stand for? The USA Principle is a common sense approach to automation and process improvement projects. U means understand the existing process, S stands for simplify the process, and A stands for automated the process. - The text lists ten strategies for automation and process improvement. Identify five of these strategies. The ten strategies listed in the text are (1) specialization of operations, (2) combined operations, (3) simultaneous operations, (4) integration of operations, (5) increased flexibility. -What are the three phases of a typical automation migration strategy? As defined in the text, the three typical phases are the following: Phase 1: Manual production using single-station manned cells operating independently. Phase 2: Automated production using single-station automated cells operating independently. Phase 3: Automated integrated production using a multistation automated system with serial operations and automated transfer of work units between stations. -What is manufacturing? The technological definition is the following: Manufacturing is the application of physical and chemical processes to alter the geometry, properties, and/or appearance of a given starting material to make parts or products; manufacturing also includes the joining of multiple parts to make assembled products. The economic definition is the following: Manufacturing is the transformation of materials into items of greater value by means of one or more processing and/or assembly operations. -What are the three basic industry categories? (1) Primary industries, which are those that cultivate and exploit natural resources, such as agriculture and mining; (2) secondary industries, which convert the outputs of the primary industries into products; they include manufacturing, construction, and power generation; and (3) tertiary
industries, which constitute the service sector of the economy, which
includes banking, retail, transportation, education, government, and so on. - What is the difference between a processing operation and an assembly operation? A processing operation transforms a work material from one state of completion to a more advanced state that is closer to the final desired part or product. It adds value by changing the geometry, properties, or appearance of the starting material. An assembly operation joins two or more components to create a new entity, called an assembly, subassembly, or some other term that refers to the joining process. -Name the four categories of part-shaping operations, based on the state of the starting work material. (1) solidification processes, (2) particulate processing, (3) deformation processes, and (4) material removal processes. -Assembly operations can be classified as permanent joining methods and mechanical assembly. What are the four types of permanent joining methods? (1) welding, (2) brazing, (3) soldering, and (4) adhesive bonding. -What is the difference between a single-model production line and a mixed-model production line? A single-model production line makes products that are all identical. A mixed-model production line makes products that have model variations characterized as soft product variety. -What is lean production? Lean production means operating the factory with the minimum possible resources and yet maximizing the amount of work that is accomplished with these resources. Lean production also implies completing the products in the minimum possible time and achieving a very high level of quality, so that the customer is completely satisfied. In short, lean production means doing more with less, and doing it better. -In lean production, what is just-in-time delivery of parts? just-in-time delivery of parts refers to the manner in which parts are moved through the production system when a sequence of manufacturing operations is required to make them. In the ideal just-in-time system, each part is delivered to the downstream workstation immediately before that part is needed at the station. -In lean production, what does worker involvement mean? worker involvement means that workers are assigned greater responsibilities and are provided with training that allows them to be flexible in the work they can do. Also, workers participate in problem-solving exercises to address issues faced by the company -In lean production, what does continuous improvement mean, and how is it usually accomplished? Continuous improvement involves an unending search for ways to make improvements in products and manufacturing operations. It is usually accomplished by worker teams who cooperate to develop solutions to production and quality problems. -What is the cycle time in a manufacturing operation? the cycle time Tc is the time that one work unit spends being processed or assembled. It is the time between when one work unit begins processing (or assembly) and when the next unit begins. -What is a bottleneck station? The bottleneck station is the slowest workstation in a production line, and therefore it limits the pace of the entire line. -What is production capacity? production capacity is the maximum rate of output that a production facility (or production line, work center, or group of work centers) is able to produce under a given set of assumed operating conditions. -How can plant capacity be increased or decreased in the short term? (1) change the number of work shifts per week Sw or (2) change the number of hours worked per shift Hsh. -What is utilization in a manufacturing plant? Utilization is the amount of output of a production facility relative to its capacity. Expressing this as an equation, U = Q/PC, where U = utilization, Q = actual output quantity produced during the period of interest, and PC is the production capacity during the same period
Tc= To+ Th+ Tth; Tc= cycle time,
To= processing time for the operation, Th= handling time (e.g., loading and unloading the production machine) Tth= tool handling time (e.g., time to change tools) Average Production Time and Rate Batch production: batch time Tb= Tsu+ QTc Average production time per work unit Tp= Tb/Q Tp= Tsu/Q+ Tc Production rate Rp= 1/Tp Cycle Time and Production Time High quantity production (if Tpin minutes): since Tsu/Q 0, Tp= Tc Rp= Rc= 60/Tp(per hour) Job shop production Q = 1: Tp= Tsu+ Tc Flow line production (if Tr is time to transfer parts between workstations): Tc= Tr+ Max To and Rc= 60/Tc Production Capacity Define: no : number of operations in the routing n: number of workstations working in parallel Sw: shifts per week, Hs: hours per shift, PCw: weekly plant capacity, units/wk Then, For facilities in which parts are made in more than one operation, no > 1: PC (w)= nSwHsRp/n0 no = 1: PC (w)= nSwHsRp Utilization and Availability Given: MTBF = mean time between failures, MTTR = mean time to repair, Q = quantity actually produced, PC = plant capacity Utilization: U= PC/Q Availability: A= MTBF-MTTR/MTBF Manufacturing Lead Time MLT= no(Tsu+ QTc+ Tno) where MLT= manufacturing lead time, no= number of operations, Tsu= setup time, Q= batch quantity, Tccycle time per part, and Tno= non-operation time WIP= WIP= AU(PC)MLT/SwHsh Define: WIP= work-in-process, pc, A= availability, U= utilization, PC= plant capacity, pc/wk, MLT= manufacturing lead time, hr, Sw= shifts per week, Hsh= hours per shift, hr/shift Costs of Manufacturing Operations Two major categories of manufacturing costs: 1.Fixed costs -remain constant for any output level 2.Variable costs -vary in proportion to production output level Velocity of piston = Volumetric flow rate / Area of Cylinder cross section, v=Q/A Rotational Hydraulic Piston Resolution of ADC
Rotational Speed = proportionality constant X volumetric flow rate,
w=KQ Force is fluid pressure by cross sectional area, F=pA Adding fixed and variable costs TC= FC+ VC(Q) where TC= total costs, FC= fixed costs (e.g., building, equipment, taxes), VC= variable costs (e.g., labor, materials, utilities), Q= output level. Unit Cost UC= TC/Q Overhead Rates Factory overhead rate: FOHR = FOHC/DLC Corporate overhead rate: COHR = COHC/DLC where DLC = direct labor costs Uniform Annual Cost, Capital Recovery Factor and Machine Rate (A/P,i,n): Capital Recovery Factor to annual interest rate, i: interest rate (or rate of return), n: number of years of service life (A/P,i,n)=(1+)(1+)1, (interest table available) UAC: Uniform Annual Cost Cm: Machine Rate (hr/yr), CL: direct labor rate ($/hr) UAC=IC x (A/P,i,n) Cm=UAC/(work hrs/yr) Cost of Equipment Usage Hourly cost of worker-machine system: Co= CL(1 + FOHRL) + Cm(1 + FOHRm) where Co= hourly rate, $/hr; CL= labor rate, $/hr; FOHRL= labor factory overhead rate, Cm= machine rate, $/hr; FOHRm= machine factory overhead rate spindle speed [ rev/min]= cutting speed[m/min]/circum milling cutter.. N= ]v (m/min)]/ pi*D Feed rate calculation Fr (mm/min_ = N (rev/min) x nf (teeth) x f (mm/tooth) Vt= fr= lead screw rotational speed x leadscrew pitch=N x p Theta =360/ (ns ( # of motor step angles) Open Loop Lathe Pulse Frequency fp Fp= nsrgfr/60p.. N= fr/p Closed Loop Lathe Calculation Fp=ns x fr/60p Controller and System Resolution Computer Controller: System Resolution: 1/(2^B- 1) Number of bits 32 used or 64 CR= max (CR1,CR2) Torque-Speed Calculation where E K and K is the voltage constant of the motor T=K I where K is the torque constant of the motor Torque-Speed Calculation