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Tutorial #2

The document contains 4 problems related to facilities design and material handling systems. Problem 1 asks to calculate the number of machines needed to meet demand given processing times and constraints. Problem 2 asks to calculate machine fractions for 3 machines producing 2 parts given standard times, scrap estimates, efficiencies, and production demands. Problem 3 asks to determine the operator-machine assignment that maximizes cost per unit given operation parameters for 2 products. Problem 4 asks several questions about assigning operators to machines given loading/unloading times and costs to minimize cost per unit produced.

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Omar Abu-obialla
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76 views

Tutorial #2

The document contains 4 problems related to facilities design and material handling systems. Problem 1 asks to calculate the number of machines needed to meet demand given processing times and constraints. Problem 2 asks to calculate machine fractions for 3 machines producing 2 parts given standard times, scrap estimates, efficiencies, and production demands. Problem 3 asks to determine the operator-machine assignment that maximizes cost per unit given operation parameters for 2 products. Problem 4 asks several questions about assigning operators to machines given loading/unloading times and costs to minimize cost per unit produced.

Uploaded by

Omar Abu-obialla
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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TUTORIAL #2 o [email protected].

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INDU 421: FACILITIES DESIGN AND MATERIAL HANDLING SYSTEMS


PROBLEM 1

• A part requires three processing steps on two machines in the sequence A-B-A. The demand this part is
10,000 units per year. The company operates six days per week, eight hours per day. Given the following
performance data, find the number of each machine needed to meet the demand.

Operation Machine Standard time Efficiency Reliability Defects


1 A 5 min 108% 98% 3%
2 B 3min 95% 95% 5%
3 A 3 min 90% 95% 5%

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TUTORIAL #2 o [email protected]

PROBLEM 2

• Given the following, what are the machine fractions for machines A, B and C to produce part x and y?

Machine A Machine B Machine C


Part x standard time 0.15 hr 0.25 hr 0.1 hr
Part y standard time 0.1 hr 0.1 hr 0.15 hr
Part x scrap estimate 5% 4% 3%
Part y scrap estimate 5% 4% 3%
Historical efficiency 90% 90% 95%
Reliability factor 90% 90% 95%
Equipment availability 1600 hr/year 1600 hr/year 1600 hr/year

• Part X routing is machine A, then B and then C; 110,000 parts are to be produced per year. Part Y routing
is machine B, then A and then C; 250,000 parts are to be produced per year. Setup time is 20 min and 40
min, respectively

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TUTORIAL #2 o [email protected]

PROBLEM 3

• Suppose 5 identical machines are to be used to produce two different products. The operation parameters
for the two products are as follow: 1 = 2 ; 2 = 2.5 ; 1 = 1 ; 2 = 1.5 ; 1 = 6 ; 2 = 8 . The cost parameters
are the same for each operator-machine combinations: 0 = 15 =50. Determine the method of assigning
operators to machines that maximizes the cost per unit produced.

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TUTORIAL #2 o [email protected]

PROBLEM 4

• It takes 3 minutes to load and 2 minutes to unload a machine. Inspection, Packing and travel between the
machines total 1 minute. Machine run automatically for 20 minutes. Operator cost 12perhour; machinescost30
per hour. a. What is the maximum number of machines that can be assigned an operator without creating
machine idle time during a repeating cycle? b. What assignment minimizes the cost per unit produced?
c. If 4 machines are assigned an operator what will be the cost per unit produced? d. For what range of
values for concurrent activity is the optimum assignment equal to 4?

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