5. A milling operation for a product has 20 seconds of manual processing time, 5

Question

5. A milling operation for a product has 20 seconds of manual processing time, 50 seconds of machine time, and an overlap of 12 seconds. The cutting tool used must be changed every 30 units: tool change time is 4 min. Takt time is 63 seconds and the total processing time available is 720 min. (a) What is the completion time per unit for this operation? (b) What is the production capacity for this operation? (c) Is this operation feasible? Justify your response. (d) say that setup time reduction led to the tool change time being reduced by 25%. Does this have any effect on your answer to (c)? Explain.

Explanation / Answer

(a)

Processing time = completion time per unit = machine time + manual time - overlap = 50+20 -12 = 58 sec

(b)

Producing 30 parts requires -

Capacity = 30 parts per (240+1740) sec = 30 parts per 1980 sec = 1 part in 66 sec = 3600/66 parts per hour = 54.5 parts per hour.

Note that the available time is 720 minutes. So, the capacity is (720 /60) x 54.5 = 654.5 units

(c)

1 part can be made in 66 sec while the takt time is 63 sec only. So, the cycle time is more than takt time. So, the operation is infeasible.

(d)

Now,

Producing 30 parts requires -

Capacity = 30 parts per (180+1740) sec = 30 parts per 1920 sec = 1 part in 64 sec

Still, cycle time (64 sec) is more than the takt time (63 sec) and the operation is infeasible.

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