PROBLEMS

Unattended Operation
14.1 A CNC machining center has a programmed cycle time = 25.0 min for a certain part. The time to unload the
finished part and load a starting wor unit = 5.0 min. !a" #f loading and unloading are done directly onto the
machine tool ta$le and no automatic storage capacity e%ists at the machine& what are the cycle time and hourly
production rate' !$" #f the machine tool has an automatic pallet changer so that unloading and loading can $e
accomplished while the machine is cutting another part& and the repositioning time = (0 sec& what are the total
cycle time and hourly production rate' !c" #f the machine tool has an automatic pallet changer that interfaces
with a parts storage unit whose capacity is 12 parts& and the repositioning time = (0 sec& what are the total
cycle time and hourly production rate' Also& how long does it tae to perform the loading and unloading of the
12 parts $y the human worer& and what is the time the machine can operate unattended $etween parts
changes'
Solution) !a" Tc = 25.0 * 5.0 = 30.0 min/pc
Rc = +0,(0 = 2.0 pc/hr
!$" Tc = -a%!25.0& 5.0" * 0.5 = 25.5 min/pc
Rc = +0,25.5 = 2.35 pc/hr
!c" Tc = -a%!25.0& 5.0" * 0.5 = 25.5 min/pc
Rc = +0,25.5 = 2.35 pc/hr
Time to load,unload = 12!5.0" = 60 min
UT = 12!25.5" . +0 = (0+ . +0 = 246.0 min = 4.1 hr
Determining Wor!tation "e#uirement!
14.2 A total of /000 stampings must $e produced in the press department during the ne%t three days. -anually
operated presses will $e used to complete the 0o$ and the cycle time is 2/ sec. 1ach press must $e set up $efore
production starts. 2etup time for this 0o$ is 2.0 hr. 3ow many presses and operators must $e de4oted to this
production during the three days& if there are /.5 hours of a4aila$le time per day'
Solution) The worload consists of /000 stampings at 2/ sec per piece
WL = /000!2/,+0 min" * 2!+0"n = (150 * 120 n !min" = 52.5 * 2 n !hr"
Time a4aila$le per press during the three days AT = (!/.5" = 22.5 hr
n =
52.5 2
22.5
n +

22.5n = 52.5 * 2n
20.5n = 52.5 n = 52.5,20.5 = 2.5+ rounded up to ( presses and operators
14.( A stamping plant must $e designed to supply an automoti4e engine plant with sheet metal stampings. The
plant will operate one 5.hour shift for 250 days per year and must produce 15&000&000 good 6uality stampings
annually. 7atch si8e = 10&000 good stampings produced per $atch. 2crap rate = 59. :n a4erage it taes (.0
sec to produce each stamping when the presses are running. 7efore each $atch& the press must $e set up& and it
taes 4 hr to accomplish each setup. ;resses are <09 relia$le during production and 1009 relia$le during
setup. 3ow many stamping presses will $e re6uired to accomplish the specified production'
Solution) ;roduction) WL =
15 000 000 ( (+00
1 0 05
& & ! , "
.
= 1(&15/.< hr,yr
AT = 250!5"!0.<0" = 1500 hr,yr per press
2etup) num$er $atches,yr =
15 000 000
10 000
& &
&
= 1500 $atches = 1500 setups
WL = 1500!4" = +000 hr,yr
AT = 250!5" = 2000 hr,yr per press.
n =
1( 15/ <
1500
+000
2000
& .
+ = /.(1 * (.0 = 10.(1 11 pre!!e!
14.4 A new forging plant must supply parts to the automoti4e industry. 7ecause forging is a hot operation& the plant
will operate 24 hr per day& fi4e days per wee& 50 wees per year. Total output from the plant must $e
10&000&000 forgings per year in $atches of 1250 parts per $atch. Anticipated scrap rate = (9. 1ach forging cell
will consist of a furnace to heat the parts& a forging press& and a trim press. ;arts are placed in the furnace an
<4
hour prior to forging= they are then remo4ed and forged and trimmed one at a time. :n a4erage the forging
and trimming cycle taes 0.+ min to complete one part. 1ach time a new $atch is started& the forging cell must
$e changed o4er& which consists of changing the forging and trimming dies for the ne%t part style. #t taes 2.0
hr on a4erage to complete a changeo4er $etween $atches. 1ach cell is considered to $e <+9 relia$le during
operation and 1009 relia$le during changeo4er. >etermine the num$er of forging cells that will $e re6uired in
the new plant.
Solution) ;roduction) WL =
10 000 000 0 + +0
1 0 0(
& & ! . , "
.
= 10(&0<2.5 hr,yr
AT = 50!5"!("!5"!0.<+" = 5/+0 hr,yr.
2etup) num$er $atches,yr =
10 000 000
1250
& &
= 5000 $atches,yr = 5000 setups,yr
WL = 5000!2" = 1+&000 hr,yr per cell
AT = 50!5"!("!5" = +000 hr,yr.
n =
10( 0<2 5
5/+0
1+ 000
+000
& . &
+ = 1/.<0 * 2.+/ = 20.5/ 21 $orging cell!
14.5 A plastic in0ection molding plant will $e $uilt to produce + million molded parts per year. The plant will run
three 5.hour shifts per day& fi4e days per wee& 50 wees per year. ?or planning purposes& the a4erage $atch
si8e = +000 moldings& a4erage changeo4er time $etween $atches = + hrs& and a4erage molding cycle time per
part = (0 sec. Assume scrap rate = 2 percent& and a4erage uptime proportion !relia$ility" per molding machine
= </ 9& which applies to $oth run time and changeo4er time. 3ow many molding machines are re6uired in
the new plant'
Solution) ;roduction) WL =
+ 000 000 (0 (+00
1 0 02
& & ! , "
.
= 51&020.4 hr,yr
2etup) num$er $atches,yr =
+& 000& 000
+000
= 1000 $atches = 1000 setups
WL = 1000!+" = +000 hr,yr
AT = (!5"!50"!5"!0.</" = 5520 hr,yr per machine
n =
51& 020.4 +000
5520
+
= 5./++ * 1.0(1 = <./</ 10 molding machine!
14.+ A plastic e%trusion plant will $e $uilt to produce (0 million meters of plastic e%trusions per year. The plant will
run three 5.hour shifts per day& (+0 days per year. ?or planning purposes& the a4erage run length = (000
meters of e%truded plastic. The a4erage changeo4er time $etween runs = 2.5 hr& and a4erage e%trusion speed =
15 m,min. Assume scrap rate = 19& and a4erage uptime proportion per e%trusion machine = <59 during run
time. @ptime proportion during changeo4er is assumed to $e 1009. #f each e%trusion machine re6uires 500 s6.
ft of floor space& and there is an allowance of 409 for aisles and office space& what is the total area of the
e%trusion plant'
Solution) ;roduction) WL =
(0 000 000
15 +0 1 0 01
& & ,
! " , ! . "
m yr
m hr
= ((&+/0.0 hr,yr
AT = (+0!("!5"!0.<5" = 5205 hr,yr.
Changeo4er) num$er runs,yr =
(0 000 000
(000
& & ,
,
m yr
m run
= 10&000 runs,yr = 10&000 changeo4ers,yr
WL = 10&000!2.5" = 25&000 hr,yr
AT = (+0!("!5" = 5+40 hr,yr per machine
n =
(( +/0
5205
25 000
5+40
& &
+ = 4.102 * 2.5<4 = +.<<5 / machines.
A = /!500"!1 * 409" = 4%00 $t
2

14./ ?uture production re6uirements in a machine shop call for se4eral automatic $ar machines to $e ac6uired to
produce three new parts !A& 7& and C" that ha4e $een added to the shopAs product line. Annual 6uantities and
cycle times for the three parts are gi4en in the ta$le $elow. The machine shop operates one 5.hour shift for 250
days per year. The machines are e%pected to $e <59 relia$le& and the scrap rate is (9. 3ow many automatic
$ar machines will $e re6uired to meet the specified annual demand for the three new parts'
<5
;art Annual demand -achining cycle time
A 25&000 5.0 min
7 40&000 /.0 min
C 50&000 10.0 min
Solution) AT = 250!5"!0.<5" = 1<00 hr,yr per machine
WL =
25000 5 +0
1 0 0(
40000 / +0
1 0 0(
50000 10 +0
1 0 0(
! , "
.
! , "
.
! , "
.
+

= 214/./ * 4511.0 * 55<1.1

WL = 15&54<.5 hr,yr
n = 15&54<.5,1<00 = 5.154 % machine!
14.5 A certain type of machine will $e used to produce three products) A& 7& and C. 2ales forecasts for these
products are) 52&000& +5&000& and /0&000 units per year& respecti4ely. ;roduction rates for the three products
are& respecti4ely& 12& 15& and 10 pc,hr= and scrap rates are& respecti4ely& 59& /9& and <9. The plant will
operate 50 wees per year& 10 shifts per wee& and 5 hr per shift. #t is anticipated that production machines of
this type will $e down for repairs on a4erage 10 percent of the time. 3ow many machines will $e re6uired to
meet demand'
Solution) AT = 50!10"!5"!1 . 0.10" = (+00 hr,yr per machine
WL =
52 000
12 1 0 05
+5 000
15 1 0 0/
/0 000
10 1 0 0<
&
! . "
&
! . "
&
! . "
+

= 45+1.4 * 4+5<.5 * /+<2.( = 1+&<1(.2 hr,yr

n = 1+&<1(.2,(+00 = 4 +/ 5 machine!
14.< An emergency situation has occurred in the milling department& $ecause the ship carrying a certain 6uantity of
a re6uired part from an o4erseas supplier san on ?riday e4ening. A certain num$er of machines in the
department must therefore $e dedicated to the production of this part during the ne%t wee. A total of 1000 of
these parts must $e produced& and the production cycle time per part = 1+.0 min. 1ach milling machine used
for this emergency production 0o$ must first $e set up& which taes 5.0 hr. A scrap rate of 29 can $e e%pected.
!a" #f the production wee consists of 10 shifts at 5.0 hr per shift& how many machines will $e re6uired' !$" #t
so happens that only two milling machines can $e spared for this emergency 0o$& due to other priority 0o$s in
the department. To cope with the emergency situation& plant management has authori8ed a three.shift
operation for si% days ne%t wee. Can the 1000 replacement parts $e completed within these constraints'
Solution) !a" WL =
1000 1+ +0
1 0 02
! , "
! . "
= 2/2.1 hr,w
AT = 10!5" . 5 = 50 . 5 = /5 hr,w per machine
n = 2/2.1,/5 = (.+( 4 milling machine!
!$" AT = +!("!5" . 5 = 1(< hr,w per machine
n = 2/2.1,1(< = 1.<+ 2 milling machine!. Bes& the 0o$ can $e completed.
14.10 A machine shop has dedicated one CNC machining center to the production of two parts !A and 7" used in the
final assem$ly of the companyAs main product. The machining center is e6uipped with an automatic pallet
changer and a parts carousel that holds ten parts. :ne thousand units of the product are produced per year& and
one of each part is used in the product. ;art A has a machining cycle time of 50 min. ;art 7 has a machining
cycle time of 50 min. These cycle times include the operation of the automatic pallet changer. No other
changeo4er time is lost $etween parts. The anticipated scrap rate is 8ero. The machining center is <59
relia$le. The machine shop operates 250 days per year. 3ow many hours must the CNC machining center $e
operated each day on a4erage to supply parts for the product'
Solution) Annual WL = 1000!50 * 50",+0 = 21++.+/ hr,yr
At 250 days per year& daily worload WL = 21++.+/,250 = &.6' hr/da(.
)achine *lu!ter!
14.11 The CNC grinding section has a large num$er of machines de4oted to grinding shafts for the automoti4e
industry. The grinding machine cycle taes (.+ min. At the end of this cycle an operator must $e present to
unload and load parts& which taes 40 sec. !a" >etermine how many grinding machines the worer can ser4ice
if it taes 20 sec to wal $etween the machines and no machine idle time is allowed. !$" 3ow many seconds
during the wor cycle is the worer idle' !c" Chat is the hourly production rate of this machine cluster'
<+
Solution) !a" n =
( + +0 40
40 20
. ! " +
+
= 25+,+0 = 4.2/ @se n1 = 4 grinding machine!
!$" Corer idle time IT = 25+ . 4!+0" = 25+ . 240 = 16 !ec
!c" Tc = 25+ sec = 4.2+/ min Rc = 4
+0
4 2+/ .

= 56.25 pc/hr
14.12 A worer is currently responsi$le for tending two machines in a machine cluster. The ser4ice time per machine
is 0.(5 min and the time to wal $etween machines is 0.15 min. The machine automatic cycle time is 1.<0
min. #f the worerDs hourly rate = E12,hr and the hourly rate for each machine = E15,hr& determine !a" the
current hourly rate for the cluster& and !$" the current cost per unit of product& gi4en that two units are
produced $y each machine during each machine cycle. !c" Chat is the 9 idle time of the worer' !d" Chat is
the optimum num$er of machines that should $e used in the machine cluster& if minimum cost per unit of
product is the decision criterion'
Solution) !a" Co = E12 * 2!E15" = +4&.00/hr
!$" Tc = Tm * Ts = 1.<0 * 0.(5 = 2.25 min,cycle
Rc = 2!2"
+0
2 25 .

= 10+.+/ pc,hr Cpc =

E45 ,
. ,
hr
pc hr 10+ +/
= +0.45/pc
!c" Corer engagement time,cycle = 2!Ts * Tr" = 2!0.(5 * 0.15" = 1.0 min
#dle time IT =
2 25 10
2 25
. .
.

= 0.555 = 55.5,
!d" n =
1<0 0 (5
0 (5 015
. .
. .
+
+
= 2.25,0.5 = 4.5 machine!
n1 = 4 machines) Cpc!4" = 0.5!12,4 * 15!2.25,+0" = E0.(<4,pc
n2 = 5 machines) Cpc!5" = 0.5!12 * 15%5"!0.50,+0" = E0.425,pc
@se n1 = 4 machine!
14.1( #n a machine cluster& the appropriate num$er of production machines to assign to the worer is to $e
determined. Fet n = the num$er of machines. 1ach production machine is identical and has an automatic
processing time Tm = 4.0 min. The ser4icing time Ts = 12 sec for each machine. The full cycle time for each
machine in the cell is Tc = Ts * Tm. The repositioning time for the worer is gi4en $y Tr = 5 * (n& where Tr is
in sec. Tr increases with n $ecause the distance $etween machines increases with more machines. !a"
>etermine the ma%imum num$er of machines in the cell if no machine idle time is allowed. ?or your answer&
compute !$" the cycle time and !c" the worer idle time e%pressed as a percent of the cycle time'
Solution) !a" n =
4.0!+0" 12 252
12 5 ( 1/ ( n n
+
=
+ + +
n!1/*(n" = 252
(n
2
* 1/ n .252 =0
@se 6uadratic e6uation to find n.
n =
1/ 1/ 4 ( 252
2 (
2
! "! "
! "
= .2.5( <.5< = +./+ or .12.4(
@se n = +./+ !ignore n = .12.4(" n1 = 6 machine!
!$" Tc = 252 !ec
!c" Corer portion of cycle = +!1/ * ( % +" = 210 sec
Corer idle time IT =
252 210
252

= 0.1+/ = 16.',
14.14 An industrial ro$ot will ser4ice n production machines in a machine cluster. 1ach production machine is
identical and has an automatic processing time Tm = 1(0 sec. The ro$ot ser4icing and repositioning time for
each machine is gi4en $y the e6uation !Ts * Tr" = 15 * 4n& where Ts is the ser4icing time !sec"& Tr is the
repositioning time !sec"& and n = num$er of machines that the ro$ot ser4ices. !Ts * Tr" increases with n $ecause
more time is needed to reposition the ro$ot arm as n increases. The full cycle time for each machine in the cell
</
is Tc = Ts * Tm. !a" >etermine the ma%imum num$er of machines in the cell such that machines are not ept
waiting. ?or your answer& !$" what is the machine cycle time& and !c" what is the ro$ot idle time e%pressed as a
percent of the cycle time Tc'
Solution) !a" Gi4en Tm = 1(0 sec& Tc = Tm * Ts = 1(0 * Ts
n =
1(0
15 4
s
T
n
+
+
Ce can deduce that if there were only one machine !n = 1"& then repositioning time would $e 8ero !Tr = 0".
Thus& for n = 1&
!Ts * Tr" = !Ts * 0" = Ts = 15 * 4!1" = 1< sec
2u$stituting this 4alue into the e6uation for n& we ha4e
n =
1(0 1<
15 4n
+
+
=
14<
15 4n +
15n * 4n
2
= 14<
4n
2
* 15n . 14< = 0
@se 6uadratic e6uation to find n.
n =
( ) ( )
( )
2
.15 15 4 4 14<
2 4

= .1.5/5 +.(5 = 4.51 or .5.2+
@se n = 4.51 !ignore n = .5.2+" ?or no machine waiting& n1 = 4 machine!
!$" Tc = 1(0 * 1< = 14< sec
!c" Ho$ot wor time = n!Ts * Tr" = 4!15 * 4 % 4" = 4!(1" = 124 sec
Ho$ot idle time 9 = !14< I 124",14< = 0.1+5 = 16.&,
14.15 A factory production department consists of a large num$er of wor cells. 1ach cell consists of one human
worer performing electronics assem$ly tass. The cells are organi8ed into sections within the department& and
one foreman super4ises each section. #t is desired to now many wor cells should $e assigned to each
foreman. The foremanAs 0o$ consists of two tass) !1" pro4ide each cell with a sufficient supply of parts that it
can wor for 4.0 hr $efore it needs to $e resupplied and !2" preparing production reports for each worcell.
Tas !1" taes 15.0 min on a4erage per worcell and must $e done twice per day. The foreman must schedule
the resupply of parts to e4ery cell so that no idle time occurs in any cell. Tas !2" taes <.0 min per worcell
and must $e done once per day. The plant operates one shift which is 5.0 woring hr& and neither the worers
nor the foreman are allowed to wor more than 5.0 hr per day. 1ach day& the cells continue production from
where they stopped the day $efore. !a" Chat is the ma%imum num$er of wor cells that should $e assigned to a
foreman& with the pro4iso that the wor cells are ne4er idle' !$" Cith the num$er of wor cells from part !a"&
how many idle min does the foreman ha4e each day'
Solution) 2ince the foreman must resupply each cell twice in an 5.0 hour day and also prepare a report on each
cell once each day& the foremanAs day can $e modeled as follows)
2 n!15" * 1 n !<" = 5!+0"
(+ n * < n = 450 45 n = 450 n = 10.+/. @se n1 = 10 cell!.
!$" ?oremanAs idle time each day = 450 . 45 n = 450 . 450 = 30 min
<5