Automation Production Systems and Computer Integrated Manufacturing 3rd edition Mikell P.Groover - Solutions

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 request for proposal indicates that the number of single command cycles is expected to be four times 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 80 ft/min. The pick and deposit time = 0.30 min. Assume that the number of single command cycles per
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 half of the rack system that is located closest to the input/output station, and the less active stock
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 0.5 m/s. The storage system has a 90% utilization. Determine the hourly throughput rate.
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 is 60 ft long and 2.5 ft wide. The speed at which the system revolves is 85 ft/min. Determine the
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 load = 1300 mm. The following is specified: (1) the AS/RS will consist of two aisles with one S/R
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 volumetric capacity = 0.75 ft3. Carousel speed = 100 ft/min. Average pick and deposit time for 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 storage and retrieval transactions per hour. Two alternative configurations are being considered: (1)
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 system is $75,000. Labor cost for a picker-operator is $20/hour, including fringe benefits and
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 storage = 0.75 m3, compute the ratio of the total volume of unit loads in storage relative to the total
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 flexibility. The unit load pallet dimensions are: depth (x) = 36 in and width (y) = 48 in. Maximum
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 requires 18 sec to accomplish a pick and deposit operation. Find:(a) The single-command and dual-command
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. Suppose horizontal and vertical speeds of the S/R machine are 400 ft/min and 60 ft/min, respectively. The
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 are 400 ft/min and 50 ft/min, respectively. The S/R machine requires 12 sec to accomplish a pick
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 speed of 350 ft/min and a vertical speed of 60 ft/min. The pick and deposit time = 0.25 min. Assume
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 travels at a horizontal speed of 2.5 m/s and a vertical speed of 0.5 m/s. Pick and deposit time = 20 s.
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 directly onto the machine tool table and no automatic storage capacity exists at the machine, what
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 automatic pallet changer and a parts carousel that holds ten parts. One thousand units of the product are
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 present to unload and load parts, which takes 40 sec.(a) Determine how many grinding machines the
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 cycle time is 1.90 min. If the worker's hourly rate = $12/hr and the hourly rate for each machine =
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 automatic processing time Tm = 4.0 min. The servicing time Ts = 12 sec for each machine. The full cycle
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 repositioning time for each machine is given by the equation (Ts + Tr) = 15 + 4n, where Ts is the servicing
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 the department, and one foreman supervises each section. It is desired to know many work cells should
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 be set up before production starts. Setup time for this job is 2.0 hr. How many presses and
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 quality stampings annually. Batch size = 10,000 good stampings produced per batch. Scrap rate = 5%. On
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 the plant must be 10,000,000 forgings per year in batches of 1250 parts per batch. Anticipated scrap
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 purposes, the average batch size = 6000 moldings, average changeover time between batches = 6 hrs, and
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 average run length = 3000 meters of extruded plastic. The average changeover time between runs = 2.5 hr,
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. Annual quantities and cycle times for the three parts are given in the table below. The machine shop
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 the three products are, respectively, 12, 15, and 10 pc/hr; and scrap rates are, respectively, 5%, 7%,
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 machines in the department must therefore be dedicated to the production of this part during the next
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 1.30 min and the loading/unloading operation can be accomplished in less time than this. It takes 9.0
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 transfer machine. Determine (a) Proportion downtime, (b) Average actual production rate, and (c) How
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 per occurrence is 9.5 min. It is proposed that a new computer system and associated sensors be
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 of downtime occurrence, how many occurrences of each type, and how much total time was lost for each
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 time for the machine is 0.15 min per cycle. A study of the system was undertaken, during which time
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 time for the line is 0.50 min, including transfer time between stations. Determine(a) How many parts
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 average hourly production rate?
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 processing time at each station is 36/n, where n = the number of stations. In addition, the time required to
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 submitted to locate a storage buffer between stations 15 and 16 to improve line efficiency.
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 between stations 20 and 21, respectively; and (b) The proposal is to use an asynchronous line with large
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 dwell position for this length of time.(a) At what rotational speed must the driven member of the
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 constant.Problem 16.18A 30-station transfer line has an ideal cycle time of 0.75 min, an average downtime
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 parts, determine(a) Line efficiency, and(b) Production rate of the line.Assume that the downtime (Td =
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) The maximum possible line efficiency and production rate that would result from installing the
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 average downtime per breakdown is expected to be 5.0. An option under consideration is to divide 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 a total of 42 hours, and a total of 1689 parts were completed. The accompanying table lists the
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 $6.00/hr to the operating cost of the line. Does the improvement in production rate justify this
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 and the downtime per line stop is 10.0 min. These values are applicable for both the one-stage and
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 breakdowns for all stations is equal (pi = p for all stations) and that the downtime is constant. To
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 for each station is 0.01. The average downtime per stop is 8.0 minutes, and a constant downtime
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 buffer between the stages will have a capacity = 3 Td/Tc. Assume a constant repair distribution.(a) For
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 dial-indexing machine has an operation time of 2.5 sec, so the table must be in a dwell position for
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 each station has an equal probability of failure. It is possible to divide the line into two stages
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 production rate in pc/hr, (b) Line efficiency, and (c) Proportion downtime.
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 tooling = $0.27/pc. Compute the average cost of a work piece produced. Problem 16.4 A ten-station
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 on the line must be changed and/or reset every 150 cycles. This procedure takes a total of 12.0 min
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) Line efficiency. Problem 16.2 A Geneva with six slots is used to operate the worktable of a
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 transfer line is located in a plant that works an 8-hr day, 5 days per week. Determine (a) Line
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. Average downtime = 8.0 min per line stop. Determine(a) Ideal production rate,(b) Frequency of line

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Automation Production Systems and Computer Integrated Manufacturing 3rd edition Mikell P.Groover - Solutions

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