Questions and Answers of Artificial Intelligence

Your company is seeking proposals for an automated storage/retrieval system that will have a throughput rate of 300 storage/retrieval transactions/hour during the one 8-hour shift per day. The
A unit load automated storage/retrieval system has five aisles. The storage racks are 60 ft high and 280 ft long. The S/R machine travels at a horizontal speed of 200 ft/min and a vertical speed of
The AS/RS aisle of Problem 11.5 will be organized following a class-based dedicated storage strategy. There will be two classes, according to activity level. The more active stock is stored in the
A single carousel storage system is located in a factory making small assemblies. It is 20 m long and 1.0 m wide. The pick and deposit time is 0.25 min. The speed at which the carousel operates is
A storage system serving an electronics assembly plant has three storage carousels, each with its own manually operated pick and deposit station. The pick and deposit time is 0.30 min. Each carousel
A unit load AS/RS is being designed to store 1000 pallet loads in a distribution center located next to the factory. Pallet dimensions are: x = 1000 mm, y = 1200 mm; and the maximum height of a unit
A single carousel storage system has an oval rail loop that is = 30 ft long and 3 ft wide. Sixty carriers are equally spaced around the oval. Suspended from each carrier are 5 bins. Each bin has a
A carousel storage system is to be designed to serve a mechanical assembly plant. The specifications on the system are that it must have a total of 400 storage bins and a throughput of at least 125
Given your answers to Problem 11.21, the costs of the two carousel systems are to be compared. The one-carousel system has an installed cost of $50,000, and the comparable cost of the two-carousel
Given the rack structure dimensions computed in Problem 11.2. Assuming that only 80% of the storage compartments are occupied on average, and that the average volume of a unit load per pallet in
A unit load AS/RS for work-in-process storage in a factory must be designed to store 2000 pallet loads, with an allowance of no less than 20% additional storage compartments for peak periods and
The length of the storage aisle in an AS/RS = 240 ft and its height = 60 ft. Suppose horizontal and vertical speeds of the S/R machine are 400 ft/min and 60 ft/min, respectively. The S/R machine
Solve Problem 11.5 except that the ratio of single-command to dual-command cycles is 3:1 instead of 1:1. Problem 11.5The length of the storage aisle in an AS/RS = 240 ft and its height = 60 ft.
An AS/RS is used for work-in-process storage in a manufacturing facility. The AS/RS has five aisles, each aisle being 120 ft long and 40 ft high. The horizontal and vertical speeds of the S/R machine
An automated storage/retrieval system installed in a warehouse has five aisles. The storage racks in each aisle are 30 ft high and 150 ft long. The S/R machine for each aisle travels at a horizontal
A 10-aisle automated storage/retrieval system is located in an integrated factory-warehouse facility. The storage racks in each aisle are 18 m high and 95 m long. The S/R machine for each aisle
What is automatic identification and data capture?
What is the difference between a passive tag and an active tag?
What are the relative advantages of RFID over bar codes?
What are the reasons why magnetic stripes are not widely used in factory floor operations?
What are the drawbacks of manual collection and entry of data?
What are the three principal components in automatic identification technologies?
Name four of the six categories of AIDC technologies that are identified in the text.
Name five common applications of AIDC technologies in production and distribution?
There are two forms of linear bar codes. Name them, and indicate what the difference is.
What is a manufacturing system?
Name the three cases of part or product variety in manufacturing systems. Briefly define each of the three cases.
What is flexibility in a manufacturing system?
What are the three capabilities that a manufacturing system must possess in order to be flexible?
Name the four components of a manufacturing system.
What are the three classifications of production machines, in terms of worker participation?
What are the five material handling functions that must be provided in a manufacturing system?
What is the difference between fixed routing and variable routing in manufacturing systems consisting of multiple workstations?
What is a pallet fixture in work transport in a manufacturing system?
A computer system is an integral component in a modern manufacturing system. Name four of the eight functions of the computer system listed in the text.
What are the five factors that can be used to distinguish manufacturing systems in the classification scheme proposed in the chapter?
Why is manning level inversely correlated with automation level in a manufacturing system?
Name three reasons why single-station manned cells are so widely used in industry.
What does the term semi-automated station mean?
What is a single-station automated cell?
What are the five enablers that are required for unattended operation of a single-model or batch-model automated production cell?
What are the additional three enablers that are required for unattended operation of a mixed-model automated production cell?
What is a machining center? Discuss.
What are some of the features on a NC machining center used to reduce nonproductive time in the work cycle?
What is a machine cluster?
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 work unit = 5.0 min. (a) If loading and unloading are done
A machine shop has dedicated one CNC machining center to the production of two parts (A and B) used in the final assembly of the company's main product. The machining center is equipped with an
The CNC grinding section has a large number of machines devoted to grinding shafts for the automotive industry. The grinding machine cycle takes 3.6 min. At the end of this cycle an operator must be
A worker is currently responsible for tending two machines in a machine cluster. The service time per machine is 0.35 min and the time to walk between machines is 0.15 min. The machine automatic
In a machine cluster, the appropriate number of production machines to assign to the worker is to be determined. Let n = the number of machines. Each production machine is identical and has an
An industrial robot will service n production machines in a machine cluster. Each production machine is identical and has an automatic processing time Tm = 130 sec. The robot servicing and
A factory production department consists of a large number of work cells. Each cell consists of one human worker performing electronics assembly tasks. The cells are organized into sections within
A total of 7000 stampings must be produced in the press department during the next three days. Manually operated presses will be used to complete the job and the cycle time is 27 sec. Each press must
A stamping plant must be designed to supply an automotive engine plant with sheet metal stampings. The plant will operate one 8hour shift for 250 days per year and must produce 15,000,000 good
A new forging plant must supply parts to the automotive industry. Because forging is a hot operation, the plant will operate 24 hr per day, five days per week, 50 weeks per year. Total output from
A plastic injection molding plant will be built to produce 6 million molded parts per year. The plant will run three 8hour shifts per day, five days per week, 50 weeks per year. For planning
A plastic extrusion plant will be built to produce 30 million meters of plastic extrusions per year. The plant will run three 8hour shifts per day, 360 days per year. For planning purposes, the
Future production requirements in a machine shop call for several automatic bar machines to be acquired to produce three new parts (A, B, and C) that have been added to the shop's product line.
A certain type of machine will be used to produce three products: A, B, and C. Sales forecasts for these products are: 52,000, 65,000, and 70,000 units per year, respectively. Production rates for
An emergency situation has occurred in the milling department, because the ship carrying a certain quantity of a required part from an overseas supplier sank on Friday evening. A certain number of
Name three of the four conditions under which automated production lines are appropriate.
What is the difference between a unitized production line and a link line?
What are the three problem areas that must be considered in the analysis and design of an automated production line?
What is starving on an automated production line?
In the operation of an automated production line with storage buffers, what does it mean if a buffer is nearly always empty or nearly always full?
What is an automated production line?
What is a pallet fixture, as the term is used in the context of an automated production line?
What is a dial-indexing machine?
Name three reasons for including a storage buffer in an automated production line?
What are the three basic control functions that must be accomplished to operate an automated production line?
A rotary worktable is driven by a Geneva mechanism with five slots. The driver rotates at 48 rev/min. Determine(a) The cycle time,(b) Available process time, and(c) Indexing time each cycle.
A ten-station rotary indexing machine performs nine machining operations at nine workstations, and the tenth station is used for loading and unloading parts. The longest process time on the line is
A transfer machine has six stations that function as follows:In addition, transfer time = 0.18 min. Average downtime per occurrence = 8.0 min. A total of 20,000 parts must be processed through the
The cost to operate a certain 20-station transfer line is $72/hr. The line operates with an ideal cycle time of 0.85 min. Downtime occurrences happen on average once per 14 cycles. Average downtime
A 23-station transfer line has been logged for 5 days (total time = 2400 min). During this time there were a total of 158 downtime occurrences on the line. The accompanying table identifies the type
An eight-station rotary indexing machine performs the machining operations shown in the accompanying table, together with processing times and breakdown frequencies for each station. The transfer
A 14-station transfer line has been logged for 2400 min to identify type of downtime occurrence, how many occurrences, and time lost. The results are presented in the table below. The ideal cycle
A transfer machine has a mean time between failures (MTBF) = 50 minutes and a mean time to repair (MTTR) = 9 minutes. If the ideal cycle rate = 1/min (when the machine is running), what is the
A part is to be produced on an automated transfer line. The total work content time to make the part is 36 minutes, and this work will be divided evenly amongst the workstations, so that the
A 30-station transfer line has an ideal cycle time of 0.75 min, an average downtime of 6.0 min per line stop occurrence, and a station failure frequency of 0.01 for all stations. A proposal has been
Given the data in Problem 16.18, solve the problem except that (a) The proposal is to divide the line into three stages, that is, with two storage buffers located between stations 10 and 11, and
A Geneva with six slots is used to operate the worktable of a dial-indexing machine. The slowest workstation on the dial-indexing machine has an operation time of 2.5 sec, so the table must be in a
In Problem 16.18, if the capacity of the proposed storage buffer is to be 20 parts, determine(a) Line efficiency, and(b) Production rate of the line.Assume that the downtime (Td = 6.0 min) is a
Solve Problem 16.20 but assume that the downtime (Td = 6.0 min) follows the geometric repair distribution.Problem 16.20In Problem 16.18, if the capacity of the proposed storage buffer is to be 20
In the transfer line of Problems 16.20 and 16.22, suppose it is more technically feasible to locate the storage buffer between stations 11 and 12, rather than between stations 15 and 16. Determine(a)
A proposed synchronous transfer line will have 20 stations and will operate with an ideal cycle time of 0.5 min. All stations are expected to have an equal probability of breakdown, p = 0.01. The
A two-week study has been performed on a 12-station transfer line that is used to partially machine engine heads for a major automotive company. During the 80 hours of observation, the line was down
In Problem 16.24, the current line has an operating cost of $66.00/hr. The starting work part is a casting that costs $4.50/pc. Disposable tooling costs $1.25/pc. The proposed storage buffer will add
A 16-station transfer line can be divided into two stages by installing a storage buffer between stations 8 and 9. The probability of failure at any station is 0.01. The ideal cycle time is 1.0 min
The uptime efficiency of a 20 station automated production line is only 40%. The ideal cycle time is 48 sec, and the average downtime per line stop occurrence is 3.0 min. Assume the frequency of
An automated transfer line is divided into two stages with a storage buffer between them. Each stage consists of 9 stations. The ideal cycle time of each stage = 1.0 minute, and frequency of failure
In Problem 16.17, suppose that a two-stage line were to be designed, with an equal number of stations in each stage. Work content time will be divided evenly between the two stages. The storage
Solve the previous problem except that the Geneva has eight slots.Previous problemA Geneva with six slots is used to operate the worktable of a dial-indexing machine. The slowest workstation on the
A 20station transfer line presently operates with a line efficiency E = 1/3. The ideal cycle time = 1.0 min. The repair distribution is geometric with an average downtime per occurrence = 8 min, and
A ten-station transfer machine has an ideal cycle time of 30 sec. The frequency of line stops is 0.075 stops per cycle. When a line stop occurs, the average downtime is 4.0 min. Determine (a) Average
Cost elements associated with the operation of the ten-station transfer line in Problem 16.4 are as follows: raw work part cost = $0.55/pc, line operating cost = $42.00/hr, and cost of disposable
In Problem 16.4, the line stop occurrences are due to random mechanical and electrical failures on the line. Suppose that in addition to these reasons for downtime, that the tools at each workstation
The dial indexing machine of Problem 16.2 experiences a breakdown frequency of 0.06 stops/cycle. The average downtime per breakdown is 3.5 min. Determine (a) Average production rate in pc/hr and (b)
In the operation of a certain 15-station transfer line, the ideal cycle time = 0.58 min. Breakdowns occur at a rate of once every 20 cycles, and the average downtime per breakdown is 9.2 min. The
A 22-station in-line transfer machine has an ideal cycle time of 0.35 min. Station breakdowns occur with a probability of 0.01. Assume that station breakdowns are the only reason for line stops.

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