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Niebels Methods, Standards and Work Design 13th edition Andris Freivalds, Benjamin Niebel - Solutions
How does the operation process chart show materials introduced into the general flow?
How does the flow process chart differ from the operation process chart?
What is the principal purpose of the flow process chart?
What symbols are used in constructing the flow process chart?
Why is it necessary to construct process charts from direct observation as opposed to information obtained from the foreman?
In the construction of the flow process chart, what method can be used to estimate distances moved?
How can delay times be determined in the construction of the flow process chart? Storage times?
Based on the following crash cost table, what would be the minimum time to complete the project described by Figure 2-4, whose normal costs are shown in Table 2-2? What would be the added cost to complete the project within this time period?
A study reveals the following steps in the assembly of a truss (small triangle 0f 3 small pieces within a large triangle of 3 larger pieces):forklift delivers 2x4 pieces of pine from outside storage area (20 min)bandsaw operator cuts 6 pieces to appropriate length (10 min)assembler #1 gets 3 short
The current operation consists of the following elements:Operator removes pressed unit (0.2 min)Operator walks to inspection area, checks for defects (0.1 min)Operator files rough edges (0.2 min)Operator places unit on conveyor for further processing and returns to press (0.1 min)Operator cleans
Given the following OSHA recordable (i.e. those that must be recorded on the OSHA 200 log and open to inspection) injuries by job code and type of injury from January 1, 1997 to September 1, 1998, what can you conclude about the injuries? Which job code would you study first? I.e. if you had
Exploratory analysis has identified the following job as a problem area. Complete a flow process chart (material type) for the following engine stripping, cleaning and degreasing operation. Engines are stored in the old-engine store room. When needed an engine is picked up by an electric hoist on a
Given the following operations and unit times in minutes (#1 = 1.5, #2 = 3, #3 = 1, #4 = 2, #5 = 4), balance the production line with the goal of producing 30 units/hr.
The following activities and times (in minutes) were recorded for a mold operator:- removes molded piece from die 0.6- walks 10 ft to a workbench 0.2- boxes widget and places on conveyor 1.0- walks back to molder 0.2- blows out dirt from mold 0.4- sprays oil into mold, pushes "GO" 0.2- mold cycles
TOYCO produces toy shovels on a 20-ton press. The steps taken by the press operator to produce one shovel are:- remove finished shovel and put on conveyor 0.1 min- remove debris from the dies 0.2 min- spray dies with oil 0.1 min- checks raw material (flat sheet) for defects 0.3 min- places flat
In the project shown below, activities are represented by arrows, and the number for each activity also indicates its normal duration (in days).a) Determine the critical path and the length of this project.b) Assume that each activity, except 1 and 2, can be crashed up to 2 days at a cost equal to
ToolCO manufactures Philips (P), Torx (T) and Flathead (F) screwdrivers in different sizes (1,2,3,4,5). The IE manager is concerned about high product defect rates but has limited resources to address all the problems. Given the following data (defects per batch of 100), identify the product
The following activities were observed for a mold operator:a) operator removes molded piece from die,b) walks to bench, puts the piece into box and the puts the box on a pallet,c) returns to injection molder,d) blows out dirt from die (with compressed air) ,e) sprays oil into die,f) presses START
The machining time per piece is 0.164 hours and the machine loading time is 0.038 hours. With an Operator rate of $12.80 per hour and a machine rate of $14 per hour, calculate the optimum number of machines for lowest cost per unit of output.
Delpack manufactures 15 different wire harnesses for the Big 3 automakers (coded as B1, B2, and B3). The wire harnesses are also coded by their current draw in amps (A1, A2, A3, A4 and A5). Given the following defect data (defects per batch of 100), indicate if there is a problem and where is
Complete a flow process chart for a press operator: 1) Removes completed widget from press 2) Feels widget edges for roughness 3) Walks to a work bench and gets file 4) Files rough edges on widget 5) Uses compressed air to blow away filing 6) Walks back to press, places widget on conveyor 7)
The following activities and times (in minutes) were recorded for a press operator: removes completed widget from press (0.1), files rough edges on widget (0.4), blows filings from widget (0.3), places widget on conveyor to next station (0.1), places raw blank into press and pushes "GO" (0.1),
An injector machine goes down roughly 20% of the time (the injector gums up and needs to be cleaned, a quick process). One operator is assigned to service three identical such machines. Each machine can produce 100 parts/hr if running properly (i.e. not down). The operator is paid $10.00/hr and
The following activities and times (in minutes) were recorded for a press operator: - removes completed widget from press, 0.1 - inspects widget, 0.4 - places widget on conveyor to next station, 0.2 - places raw blank into press and pushes "GO", 0.1 - press cycles automatically for, 2.0 The cycle
A not-so-well-maintained machine is down roughly 40% of the time. One operator is assigned to service four identical such machines. Each machine can produce 60 widgets/hr if running (i.e. not completely idle). The operator is paid $10.00/hr and each machine costs $20.00/hr for power and supplies.a)
At Dorben Company, a worker is assigned to operate several machines. Each of these machines is down at random times during the day. A work sampling study indicated that on the average the machines operate 60 percent of the time unattended. Operator attention time at irregular intervals averages 40
The analyst in the Dorben Company wishes to assign a number of like facilities to an operator based on minimizing the cost per unit of output. A detailed study of the facilities revealed the following: Loading machine standard time = 0.34 minutes Unloading machine standard time = 0.26
A study revealed that a group of three semiautomatic machines assigned to one operator operate 70 percent of the time unattended. Operator service time at irregular intervals averaged 30 percent of the time on these three machines. What would be the estimated machine hours lost per eight-hour day
Based upon the following data, develop your recommended allocation of work and the number of work stations.
How many machines should be assigned to an operator for lowest cost operations when:a. Loading and unloading time one machine, 1.41 minutes.b. Walking time to next facility, 0.08 minutes.c. Machine time (power feed), 4.34 minutes.d. Operator rate, $13.20 per hour.e. Machine rate, $18.00 per hour.
What proportion of machine time would be lost in operating four machines when the machine operates 70 percent of the time unattended and the operator attention time at irregular intervals averages 30 percent? Is this the best arrangement on the basis of minimizing the proportion of machine time
In an assembly process involving six distinct operations, it is necessary to produce 250 units per eight-hour day. The measured operation times are as follows: a. 7.56 minutes. b. 4.25 minutes. c. 12.11 minutes d. 1.58 minutes. e. 3.72 minutes. f. 8.44 minutes. How many operators would be required
Explain how design simplification can be applied to the manufacturing process.
When is an elaborate quality control procedure not justified?
What six points should be considered when endeavoring to reduce material cost?
How does a changing labor and equipment situation affect the cost of purchased components?
Explain how rearranging operations can result in savings.
What process is usually considered the fastest for forming and sizing operations?
How should the analyst investigate the setup and tools to develop better methods?
Give some applications of bar coding for the improvement of productivity.
What are the two general types of plant layout? Explain each in detail.
What is the best way to test a proposed layout?
Which questions should the analyst ask when studying work performed at a specific workstation?
How is operation analysis related to methods engineering?
Explain the advantages of using a checklist.
Why do costs vary little with distance in connection with automated guided vehicles?
On what does the extent of tooling depend?
How can planning and production control affect set-up time?
How can you best handle a material?
How is the travel chart related to Mother's SLP?
Why does the travel chart have more application in process layout than in product layout?
Explain the fundamental purpose of group technology.
Explain how the conservation of welding rod can result in 20 percent material savings.
Identify several automobile components with which you are familiar that have been converted from metal to plastic in recent years.
How do unnecessary operations develop in an industry?
Where would you find application for a hydraulic elevating table?
What is the difference between a skid and a pallet?
Compare and contrast operations analysis with the lean manufacturing approach.
What are the seven mudas?
What are the 5S pillars?
What is meant by 'tight' tolerances?
Explain why it may be desirable to "tighten up" tolerances and specifications.
What is meant by lot-by-lot inspection?
The finish tolerance on the shaft in Figure 3-4 was changed from 0.004 inches to 0.008 inches. How much cost improvement resulted from this change?
The Dorben Company is designing a cast-iron part whose strength T is a known function of the carbon content C, where: T=2C2+¾C-C3+k. To maximize strength, what carbon content should be specified?
To make a given part interchangeable, it was necessary to reduce the tolerance on the outside diameter from ±0.010 to ±0.005 at a resulting cost increase of 50 percent of the turning operation. The turning operation represented 20 percent of the total cost. By making the part interchangeable, the
The Dorben Group suite consists of five rooms having areas and relationships shown below. Obtain an optimal layout using Muther's SLP and SPIRAL. Compare and contrasts the resulting layouts.
Using the from-to chart showing the number of units handled from one area to another per hour and the desired size of each area (in square feet), develop an optimal layout using Muther's SLP. Note that you will need devise a relationship scheme for the given flows. Also, * means an undesirable
Using Muther's SLP and the data shown below for a small machine shop, develop the best final layout to scale within the outer walls of the building shown below. Areas in square feet are: RM=1,000; Saw =500, Lathe=500, Drill=500, Mill=500, Ins=1,000. Show all the steps in Muther's SLP and draw your
a. Using the following operations and elemental times (Op#1=0.3 Op#2=0.4 Op#3=0.3 Op#4=0.6 OP#5=0.4 minutes), develop a set of workstations that would most efficiently balance the production line and decrease the idle time. Management hopes to have 120 units produced per hour. What was the % idle
Using Muther's SLP and the flow data shown below for a small machine shop, develop the best final layout to scale (use the grid) within the outer walls of the building shown below. Place your final layout in the empty floor plan (keeping the area, but necessarily the shape, for each room the same).
What structural components are found in muscles? What do these components have to do with muscle performance?
What basic motion generally precedes 'reach'?
What three variables affect the time for the basic motion 'move'?
How does the analyst or observer determine when the operator is performing the element 'inspect'?
Explain the difference between avoidable and unavoidable delays.
Which of the 17 therbligs are classed as effective, and usually cannot be removed from the work cycle?
Why should fixed locations be provided at the workstation for all tools and materials?
Which of the five classes of motions is preferred for industrial workers? Why?
Why is it desirable to have the feet working only when the hands are occupied?
What task factors increase the index of difficulty in a Fitts' Tapping Task?
What task factors increase the index of difficulty in a Fitts' Tapping Task? Discuss.
Explain elements of static and dynamic muscle performance with the sliding filament theory.
What factors affect back compressive forces during lifting?
What factors influence your measurement of isometric muscle strength?
Why do psychophysical, dynamic and static strength capabilities differ?
What methods can be used to estimate the energy requirements of a job?
What factors change the energy expended for a given job?
How does work capability vary with gender and age?
What limits endurance in a whole body manual task?
Describe the different types of muscle fibers and relate their properties with muscle performance.
Why does a change in the number of active motor units not result in a proportional change in muscle tension?
What does EMG measure? How is EMG interpreted?
Explain why workstation designers should endeavor to have operators perform work elements without having to lift their elbows.
What viewing distance would you recommend for a seated operator working at a computer terminal?
Define and give examples of the 17 fundamental motions, or therbligs.
How may the basic motion 'search' be eliminated from the work cycle?
What is the maximum load that can be raised by an outstretched stiff arm by a 50th percentile female?
A standing inspector picks up 25 lb castings from a conveyor 50 inches from the floor with a horizontal distance of 20 inches. He then puts the casting on a work area 20 inches lower than the conveyor and closer to the body (a minimum horizontal distance) for inspection. For good ones, he twists
Consider a worker standing on the ground lifting crates of vegetables (10 in. high and 10 in. deep, 30 lbs) from the ground to the flat bed of the truck where another worker will move the box and position it properly in the truck. Assume that the lift from the ground is fairly optimal, but that the
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