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Automation Production Systems and Computer Integrated Manufacturing 3rd edition Mikell P.Groover - Solutions
Name four of the six reasons for using a CAD system to support the engineering design function?
Give some examples of engineering analysis software in common use on CAD systems.
What is rapid prototyping?
What is virtual prototyping?
Name four of the seven important applications of CAM in manufacturing planning?
What is process planning?
Design for Manufacturing and Assembly (DFM/A) includes two aspects: (1) organizational changes and (2) design principles and guidelines. Identify two of the organizational changes that might be made in implementing DFM/A?
Name five of the eleven universal design guidelines in DFM/A.
Name three of the four activities often included within the scope of advanced manufacturing planning?
Name four of the seven decisions and details that are usually included within the scope of process planning?
A typical process sequence for a manufactured part consists of four types of operations. Name and briefly describe the four types of operations.
Name five of the eight factors that influence the make-or-buy decision?
Name three of the five benefits derived from computer-aided process planning?
Briefly describe the two basic approaches in computer-aided process planning.
What is concurrent engineering?
What is production planning?
What is capacity planning?
Capacity adjustments can be divided into short-term adjustments and long-term adjustments. Name four of the capacity adjustments for the short term?
What is shop floor control?
What are the three phases of shop floor control? Provide a brief definition of each activity.
What are carrying costs in inventory control?
What is a reorder point system in inventory control?
What is enterprise resource planning (ERP)?
Name three of the four activities within the scope of production planning?
What is production control?
What is the difference between the aggregate production plan and the master production schedule?
What is material requirements planning (MRP)?
What is the difference between independent demand and dependent demand?
What are the three main inputs to the MRP processor?
What are common use items in MRP?
Name three benefits of a well-designed MRP system?
The annual demand for a certain part is 2000 units per year. The part is produced in a batch model manufacturing system. Annual holding cost per piece is $3.00. It takes 2 hours to set up the machine to produce the part, and cost of system downtime is $150/hr. Determine (a) The most economical
A work part costing $80 is processed through the factory. The manufacturing lead time for the part is 12 weeks, and the total time spent in processing during the lead time is 30 hours for all operations at a rate of $35 per hour. Noncooperation costs total $70 during the lead time. The holding cost
A batch of large castings is processed through a machine shop. The batch size is 20. Each raw casting costs $175. There are 22 machining operations performed on each casting at an average operation time of 0.5 hour per operation. Setup time per operation averages 5 hours. The cost rate for the
Using the master schedule, and the product structures, determine the time-phased requirements for component C6 and raw material M6. The raw material used in component C6 is M6. Lead times are as follows: for P1, assembly lead time is 1 week; for P2, assembly lead time is 1 week; for S2, assembly
Solve previous Problem 25.12 except that the current inventory on hand and on order for S3, C6, and M6 is as follows: for S3, inventory on hand is 2 units and quantity on order is zero; for C6, inventory on hand is 5 units and quantity on order is 10 for delivery in week 2; and for M6, inventory on
Material requirements are to be planned for component C2 given the master schedule for P1 and P2, and the product structures in. Assembly lead time for products and subassemblies (P and S levels) is 1 week, manufacturing lead times for components (C level) is 2 weeks, and ordering lead time for raw
Requirements are to be planned for component C5 in product P1. Required deliveries for P1 are given, and the product structure for P1. Assembly lead time for products and subassemblies (P and S levels) is 1 week, manufacturing lead times for components (C level) is 2 weeks, and ordering lead time
Solve previous Problem 25.15 except that the following additional information is known: scheduled receipts of M5 are 50 units in week 3 and 50 units in week 4.
It is currently day 10 in the production calendar of the XYZ Machine Shop. Three orders (A, B, and C) are to be processed at a particular machine tool. The orders arrived in the sequence ABC. The table below indicates the process time remaining and production calendar due date for each order.
In previous Problem 25.17, for each solution, (a) through (e), determine which jobs are delivered on time and which jobs are tardy.
Annual demand for a made to stock product is 60,000 units. Each unit costs $8.00 and the annual holding cost rate is 24%. Setup time to change over equipment for this product is 6 hr, and the downtime cost of the equipment is $120/hr. Determine (a) Economic order quantity and (b) Total inventory
Demand for a certain product is 25,000 units/yr. Unit cost is $10.00. Holding cost rate is 30%/yr. Changeover (setup) time between products is 10.0 hr, and downtime cost during changeover is $150/hr. Determine (a) Economic order quantity, (b) Total inventory costs, and (c) Total inventory cost per
A part is produced in batches size of 3000 pieces. Annual demand is 60,000 pieces, and piece cost is $5.00. Setup time to run a batch is 3.0 hr, cost of downtime on the affected equipment is figured at $200/hr, and annual holding cost rate is 30%. What would the annual savings be if the product
(a) How much would setup time have to be reduced in order to make the batch size of 3000 pieces equal to the economic order quantity? (b) How much would total inventory costs be reduced if the EOQ = 3000 units compared to the EOQ calculated in the previous problem? (c) How much would total
A certain machine tool is used to produce several components for one assembled product. To keep in process inventories low, a batch size of 100 units is produced for each component. Demand for the product is 3000 units per year. Production downtime costs an estimated $150/hr. All parts produced on
Annual demand for a certain part is 10,000 units. At present the setup time on the machine tool that makes this part is 5.0 hr. Cost of downtime on this machine is $200/hr. Annual holding cost per part is $1.50. Determine (a) EOQ and (b) Total inventory costs for this data. Also, determine (c) EOQ
A variety of assembled products are made in batches on a batch model assembly line. Every time a different product is produced, the line must be changed over which causes lost production time. The assembled product of interest here has an annual demand of 12,000 units. The changeover time to set up
A two bin approach is used to control inventory for a certain low cost hardware item. Each bin holds 500 units of the item. When one bin becomes empty, an order for 500 units is released to replace the stock in that bin. The order lead time is slightly less than the time it takes to deplete the
Define lean production.
What is the basic starting point in a study to reduce setup time?
What is production leveling?
How is production leveling accomplished?
What does autonomation mean?
What is total productive maintenance?
What is a quality circle?
What is visual management?
What is an andon board?
What is the 5S system?
What is takt time?
What are standardized work procedures in the Toyota production system?
Name four of the seven forms of waste in production, as identified by Taiichi Ohno.
What are three reasons why people and materials are sometimes moved unnecessarily in production operations?
What is a just-in-time production system?
What is the difference between a push system and a pull system in production control?
What is a kanban? What are the two types of kanban?
A stamping plant supplies sheet metal parts to a final assembly plant in the automotive industry. The following data are values representative of the parts made at the plant. Annual demand is 150,000 pc (for each part produced). Average cost per piece is $18 and holding cost is 20% of piece cost.
The weekly demand for a certain part is 950 units. The plant operates 5 days per week, with an effective operating time of 440 min per day. Determine the takt time for this part.
The monthly usage for a component supplied to an appliance assembly plant is 5,000 parts. There are 21 working days in the month and the effective operating time of the plant is 450 min per day. Currently, the defect rate for the component is 2.2%, and the equipment used to produce the part is down
The monthly demand for a part produced for an automotive final assembly plant is 16,000 units. There are 20 working days in February and the effective operating time of the plant is 900 min per day (two shifts). The fraction defect rate for the component is 0.017, and the automated machine that
A supplier of parts to an assembly plant in the household appliance industry is required to make deliveries on a just-in-time basis (daily). For one of the parts that must be delivered, the daily requirement is 200 parts, five days per week, 52 weeks per year. However, the supplier cannot afford to
Monthly usage rate for a certain part is 15,000 units. The part is produced in batches and its manufacturing costs are estimated to be $7.40. Holding cost is 20% of piece cost. Currently the production equipment used to produce this part is also used to produce 19 other parts with similar usage and
An injection-molding machine used to produce 25 different plastic molded parts in a typical year. Annual demand for a typical part is 20,000 units. Each part is made out of a different plastic (the differences are in type of plastic and color). Because of the differences, changeover time between
In the previous problem, a second proposal has been made to reduce the purging time of 3.5 hours during a changeover to less than 1.5 hours by sequencing the batches of parts so as to reduce the differences in plastic type and color between one part and the next. In the ideal, the same plastic can
The following data apply to sheet metal parts produced at a stamping plant that serves a final assembly plant in the automotive industry. The data are average values representative of the parts made at the plant. Annual demand = 150,000 pc (for each part produced); average cost per piece = $20;
Given the data in the previous problem, it is desired to reduce the batch size from the value determined in that problem to 600 pieces, consistent with the number of units produced daily by the final assembly plant served by the stamping plant. Determine the changeover time that would allow the
Annual demand for a part is 500 units. The part is currently produced in batches. It takes 2.0 hours to set up the production machine for this part, and the downtime during setup costs $125/hr. Annual holding cost for the part is $5.00. The company would like to produce the part using a new
A certain production machine has an availability of 97%. Its utilization is 92%. The fraction defect rate of the parts made on the machine is 0.025, and it operates at only 85% of its rated speed. What is the overall equipment effectiveness of this machine?
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