Three possible manufacturing systems can be used to produce a certain product, 1

Question

Three possible manufacturing systems can be used to produce a certain product, 1) ten universal milling machines that work in series, each one is producing a specific geometry, 2) one dedicated broaching machine with a roller conveyor for handling, or 3) 4 CNC milling machines working independently and a shuttle for material handling.

1. Name the three manufacturing systems.

2. What are the characteristics of each system?

3. List the types of flexibility that may exist in a manufacturing system.

3. Discuss if and how the 3 systems can adapt to a change in production volume or product design.

4. Which manufacturing system is more flexible?

5. Identify and briefly discuss the various types of possible flexibility sources in that system?

6. If the capacity of a single universal milling machine is 20 unit/hr and a defect rate of 5%, 100 unit/hr for the broaching machine and a defect rate of 2%, and 20 unit/hr for a single CNC milling machine and a defect rate of 2.5%, determine the throughput of each system.

7. Make the necessary modification in number of machines in each of the 3 systems to bring throughput up to 110 unit/hr. What are the reached utilization levels?

8. After a year of operation and with the same throughput of 110 unit/hr, there is a 60% chance for a product change, which means an extra universal milling machine will be added ($100,000), a major modification to the broaching machine will be performed ($200,000), and a change to pallet shape is required in the shuttle ($100,000). Determine which system is more desirable and justify your answer, if initial investments for system 1 is $500,000, system 2 is $800,000, and system 3 is $1000,000.

Explanation / Answer

Q1:
The mype of manufacturing is:
Mass production,
Batch Production
Job Shop

Q2:

Mass production:
Mass production is the production of large amounts of standardized products, including and especially on assembly lines. With job production and batch production it is one of the three main production methods.
The concepts of mass production are applied to various kinds of products, from fluids and particulates handled in bulk (such as food, fuel, chemicals, and mined minerals) to discrete solid parts (such as fasteners) to assemblies of such parts (such as household appliances and automobiles).

Batch Production
Batch production is a technique used in manufacturing, in which the object in question is created stage by stage over a series of workstations. With job production and flow production it is one of the three main production methods.
Batch production is most common in bakeries and in the manufacture of sports shoes, pharmaceutical ingredients, purifying water (APIs), inks, paints and adhesives. In the manufacture of inks and paints, a technique called a colour-run is used. A colour-run is where one manufactures the lightest colour first, such as light yellow followed by the next increasingly darker colour such as orange, then red and so on until reaching black and then starts over again.


Job Shop:
Job shops are typically small manufacturing businesses that handle job production, that is, custom/bespoke or semi-custom/bespoke manufacturing processes such as small to medium-size customer orders or batch jobs. Job shops typically move on to different jobs (possibly with different customers) when each job is completed. By the nature of this type of manufacturing operation, job shops are usually specialized in skill and processes. In computer science the problem of job shop scheduling is considered strongly NP-hard.

Q3:
Types of Flexibility:
MachineFlexibility::::::::: It is the capability to adapt a given machine in the system to a wide range of production operations and part styles. The greater the range of operations and part styles the greater will be the machine flexibility.
Production Flexibility:::::::::::::It is the range of part styles that can be produced on the systems. The range of part styles that can be produced by a manufacturing system at moderate cost and time is determined by the process envelope
Mix Flexibility::::::::It is defined as the ability to change the product mix while maintaining the same total production quantity that is, producing the same parts only in different proportions. It is also known as process flexibility. Mix flexibility provides protection against market variability by accommodating changes in product mix due to the use of shared resources
Product Flexibility:::::: It refers to ability to change over to a new set of products economically and quickly in response to the changing market requirements. The change over time includes the time for designing, planning, tooling, and fixturing of new products introduced in the manufacturing line -up.
Routing Flexibility:::::::: It can define as capacity to produce parts on alternative workstation in case of equipment breakdowns, tool failure, and other interruptions at any particular station. It helps in increasing throughput, in the presence of external changes such as product mix, engineering changes, or new product introductions.
Volume Flexibility:::::::: It is the ability of the system to vary the production volumes of different products to accommodate changes in demand while remaining profitable.
Expansion Flexibility:::::: It is defined as the ease with which the system can be expanded to foster total production volume.


Q4:
Adaptation:
Mass production: mass production is inflexible because it is difficult to alter a design or production process after a production line is implemented. Also, all products produced on one production line will be identical or very similar, and introducing variety to satisfy individual tastes is not easy. However, some variety can be achieved by applying different finishes and decorations at the end of the production line if necessary.
Batch Production : Well the advantage of batch production is that the company that uses it has a variety of products rather than just one type so therefore it gives customer a larger choice and hence a larger possibility of sales. Another advantage is that the company is reducing its risk on simply concentrating on one product; it produces a variety of different ones of the same type. The main disadvantage of batch production is that there's a period of time for which the machinery is being changed and this causes the productivity to stop completely which the could cause the workers to sit idle; basically the work stops.
Job Shop: It is highly adaptable, can change to any condition dut to single unit operation.


Q5:
Flexibility sources:
Number of machines: We can use varied number of machines for flexibility
Material: Use of various material
Production schedule
interconnection of the machines


Q6:

Throughput:
1:the capacity of a single universal milling machine is 20 unit/hr and a defect rate of 5%,
actual capacity = summesion of production of each machine without defects. Defects cant be propagated
ex: 20 - 20 * 5% = 19, so others are calculated.
19+18+17+16+15+14+13+13+12+11 = 148 units

2:100 unit/hr for the broaching machine and a defect rate of 2%
Actual Throughput: = 100 - 5% = 95

3:20 unit/hr for a single CNC milling machine and a defect rate of 2.5%:
Actual Throughput:
4 * (20 - 2.5%) = 78 units


Q7:
For the Single universal milling machine: it already exceeds the reqired productiin, so decrease no. of machine by 3.
for broaching machine, add another machine or increase productivity.
For CNC milling machine , add 2 more machine.

Q8:
The milling machine is more desirable,
because:
We have already 10 machines, so easy handling
maintenance is easy.
lower depriciation costs.
not much structural chages necessary.

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