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Automation Production Systems and Computer Integrated Manufacturing 3rd edition Mikell P.Groover - Solutions
Name three of the four conditions under which automated assembly technology should be considered.
What are the effects of poor quality parts, as represented by the fraction defect rate, on the performance of an automated assembly system?
Why are storage buffers used on partially automated production lines?
What are the four automated assembly system configurations listed in the text?
What are the typical hardware components of a workstation parts delivery system?
What is a programmable parts feeder?
Name six typical products that are made by automated assembly.
Considering the assembly machine as a game of chance, what are the three possible events that might occur when the feed mechanism attempts to feed the next component to the assembly work head at a given workstation in a multi-station system?
A feeder-selector device at one of the stations of an automated assembly machine has a feed rate of 25 parts per minute and provides a throughput of one part in four. The ideal cycle time of the assembly machine is 10 sec. The low level sensor on the feed track is set at 10 parts, and the high
An automated assembly machine has four workstations. The first station presents the base part, and the other three stations add parts to the base. The ideal cycle time for the machine is 3 sec, and the average downtime when a jam results from a defective part is 1.5 min. The fraction defective
A six-station automatic assembly machine has an ideal cycle time of 6 sec. At stations 2 through 6, parts feeders deliver components to be assembled to a base part that is added at the first station. Each of stations 2 through 6 is identical and the five components are identical. That is, the
A six-station dial indexing machine is designed to perform four assembly operations at stations 2 through 5 after a base part has been manually loaded at station 1. Station 6 is the unload station. Each assembly operation involves the attachment of a component to the existing base. At each of the
For Example 17.4 in the text, dealing with a single-station assembly system, suppose that the sequence of assembly elements were to be accomplished on a seven-station assembly system with synchronous parts transfer. Each element is performed at a separate station (stations 2 through 6) and the
A single-station assembly machine is to be considered as an alternative to the dial-indexing machine in Problem 17.4. Use the data given in the table for that problem to determine(a) Production rate,(b) Yield of good product (final assemblies containing no defective components), and(c) Proportion
A single station robotic assembly system performs a series of five assembly elements, each of which adds a different component to a base part. Each element takes 4.5 sec. In addition, the handling time needed to move the base part into and out of position is 4 sec. For identification, the
A robotic assembly cell uses an industrial robot to perform a series of assembly operations. The base part and parts 2 and 3 are delivered by vibratory bowl feeders that use selectors to insure that only properly oriented parts are delivered to the robot for assembly. The robot cell performs the
A partially automated production line has a mixture of three mechanized and three manual workstations. There are a total of six stations, and the ideal cycle time of 1.0 min, which includes a transfer time of 6 sec. Data on the six stations are listed in the accompanying table. Cost of the transfer
Reconsider Problem 17.17 except that both the current line and the proposed line will have storage buffers before and after the manual stations. The storage buffers will be of sufficient capacity to allow these manual stations to operate independently of the automated portions of the line.
A manual assembly line has six stations. The assembly time at each manual station is 60 sec. Parts are transferred by hand from one station to the next, and the lack of discipline in this method adds 12 sec (Tr = 12 sec) to the cycle time. Hence, the current cycle time is 72 sec. The following two
Solve Problem 17.1 but use a feed rate of 32 parts per minute. Note the importance of tuning the feeder-selector rate to the cycle rate of the assembly machine. Problem 17.1 A feeder-selector device at one of the stations of an automated assembly machine has a feed rate of 25 parts per minute and
Solve preceding Problem 17.19, except that the probability that a defective part will jam the automated station is m = 0.5 for all stations.Problem 17.19A manual assembly line has six stations. The assembly time at each manual station is 60 sec. Parts are transferred by hand from one station to the
A synchronous assembly machine has 8 stations and must produce at an average rate of 400 completed assemblies per hour. Average downtime per jam is 2.5 min. When a breakdown occurs, all subsystems (including the feeder) stop. The frequency of breakdowns of the machine is once every 50 parts. One of
A dial indexing machine has six stations that perform assembly operations on a base part. The operations, element times, q and m values for components added are given in the table below (NA means q and m are not applicable to the operation). The indexing time for the dial table is 2 sec. When a jam
An eight-station assembly machine has an ideal cycle time of 6 sec. The fraction defect rate at each of the 8 stations is q = 0.015 and a defect always jams the affected station. When a breakdown occurs, it takes 1 minute, on average, for the system to be put back into operation. Determine the
Solve Problem 17.5 but assume that defects never jam the workstations. Other data are the same. Problem 17.5 An eight-station assembly machine has an ideal cycle time of 6 sec. The fraction defect rate at each of the 8 stations is q = 0.015 and a defect always jams the affected station. When a
Solve Problem 17.5 but assume that m = 0.6 for all stations. Other data are the same. Problem 17.5 An eight-station assembly machine has an ideal cycle time of 6 sec. The fraction defect rate at each of the 8 stations is q = 0.015 and a defect always jams the affected station. When a breakdown
A six-station automatic assembly line has an ideal cycle time of 12 sec. Downtime occurs for two reasons. First, mechanical and electrical failures cause line stops that occur with a frequency of once per 50 cycles. Average downtime for these causes is 3 min. Second, defective components also
An eight-station automatic assembly machine has an ideal cycle time of 10 sec. Downtime is caused by defective parts jamming at the individual assembly stations. The average downtime per occurrence is 3.0 min. The fraction defect rate is 1.0% and the probability that a defective part will jam at a
What is the composite part concept, as the term is applied in group technology?
What are the four common GT cell configurations, as identified in the text?
What is the key machine concept in cellular manufacturing?
What is the difference between a virtual machine cell and a formal machine cell?
What is cellular manufacturing?
What are the production conditions under which group technology and cellular manufacturing are most applicable?
What is a part family?
What are the three methods for solving the problem of grouping parts into part families?
What is the difference between a hierarchical structure and a chain-type structure in a classification and coding scheme?
What is production flow analysis?
What are the typical objectives when implementing cellular manufacturing?
Develop the form code (first five digits) in the Opitz System for the part.
In Problem 18.8, two logical machine groups are identified by rank order clustering. For each machine group,(a) Determine the most logical sequence of machines for this data.(b) Construct the network diagram for the data.
Five machines will constitute a GT cell. The from to data for the machines are shown in the table below.(a) Determine the most logical sequence of machines for this data, and construct the network diagram, showing where and how many parts enter and exit the system.
A GT machine cell contains three machines. Machine 1 feeds machine 2 which is the key machine in the cell. Machine 2 feeds machine 3. The cell is set up to produce a family of five parts (A, B, C, D, and E). The operation times for each part at each machine are given in the table below. The
A GT cell will machine the components for a family of parts. The parts come in several different sizes and the cell will be designed to quickly change over from one size to the next. This will be accomplished using fast change fixtures and downloading the part programs from the plant computer to
Develop the form code (first five digits) in the Opitz System for the part illustrated in Figure P18.2.
Develop the form code (first five digits) in the Opitz System for the part illustrated in Figure P18.3.
Apply the rank order clustering technique to the part-machine incidence matrix in the following table to identify logical part families and machine groups. Parts are identified by letters, and machines are identified numerically.
Apply the rank order clustering technique to the part-machine incidence matrix in the following table to identify logical part families and machine groups. Parts are identified by letters, and machines are identified numerically.
Apply the rank order clustering technique to the part-machine incidence matrix in the following table to identify logical part families and machine groups. Parts are identified by letters, and machines are identified numerically.
The following table lists the weekly quantities and routings of ten parts that are being considered for cellular manufacturing in a machine shop. Parts are identified by letters and machines are identified numerically. For the data given,(a) Develop the part-machine incidence matrix, and(b) Apply
Four machines used to produce a family of parts are to be arranged into a GT cell. The from to data for the parts processed by the machines are shown in the table below.(a) Determine the most logical sequence of machines for this data.(b) Construct the network diagram for the data, showing where
Name three production situations in which FMS technology can be applied?
The text lists five categories of layout configurations that are found in a flexible manufacturing system. Name four of the five layout configurations.
Name four of the seven functions performed by human resources in an FMS.
What are four benefits that can be expected from a successful FMS installation?
`What is a flexible manufacturing system?
What are the three capabilities that a manufacturing system must possess in order to be flexible? Discuss.
Name the four tests of flexibility that a manufacturing system must satisfy in order to be classified as flexible.
What is the difference between a dedicated FMS and a random-order FMS?
What are the four basic components of a flexible manufacturing system?
What are three of the five functions of the material handling and storage system in a flexible manufacturing system?
What is the difference between the primary and secondary handling systems that are common in flexible manufacturing systems?
A flexible manufacturing cell consists of two machining workstations plus a load/unload station. The load/unload station is station 1. Station 2 performs milling operations and consists of one server (one CNC milling machine). Station 3 has one server that performs drilling (one CNC drill press).
Use the extended bottleneck model to solve Problem 19.4 with the following number of parts in the system:(a) N = 5 parts,(b) N = 8 parts, and(c) N = 12 parts.Also determine the manufacturing lead time for the three cases of N in (a), (b), and (c).Problem 19.4Solve Problem 19.3 except the number of
For the data given in Problem 19.6, use the extended bottleneck model to develop the relationships for production rate Rp and manufacturing lead time MLT each as a function of the number of parts in the system N. Plot the relationships as in Figure 19.12.Data given in Problem 19.6The product mix
A flexible manufacturing system is used to produce three products. The FMS consists of a load/unload station, two automated processing stations, an inspection station, and an automated conveyor system with an individual cart for each product. The conveyor carts remain with the parts during their
A group technology cell is organized to produce a particular family of products. The cell consists of three processing stations, each with one server; an assembly station with 3 servers; and a load/unload station with 2 servers. A mechanized transfer system moves the products between stations. The
In Problem 19.13, compute the average manufacturing lead times for each product for the two cases:(a) N = N*, and(b) N = N* + 10. If N* is not an integer, use the integers that are closest to N* and N* + 10, respectively.Problem 19.13A group technology cell is organized to produce a particular
In Problem 19.13, what could be done to?(a) Increase the production rate and/or(b) Reduce the operating costs of the cell in light of your analysis? Support your answers with calculations.Problem 19.13A group technology cell is organized to produce a particular family of products. The cell consists
A flexible manufacturing cell consists of a manual load/unload station, three CNC machines, and an automated guided vehicle system (AGVS) with two vehicles. The vehicles deliver parts to the individual machines, drop off the parts, then go perform other work. The workstations are listed in the
A flexible manufacturing system is used to produce four parts. The FMS consists of one load/unload station and two automated processing stations (processes X and Y). The number of servers for each station type is to be determined. The FMS also includes an automated conveyor system with individual
A flexible machining system is being planned that will consist of four workstations plus a part handling system. Station 1 will be a load/unload station. Station 2 will consist of horizontal machining centers. Station 3 will consist of vertical machining centers. Station 4 will be an inspection
In Problem 19.18, determine (a) The utilizations of each station in the system for the specified production requirements, and (b) What is the maximum possible production rate of the system if the bottleneck station were to operate at 100% utilization? Problem 19.18 A flexible machining system is
Solve Problem 19.1 except the number of servers at station 2 (CNC milling machines) = 3 and the number of servers at station 3 (CNC drill presses) = 2. With the increase in the number of machines from two to five, the FMC is now a FMS according to our definitions in Section 19.1.2.Problem 19.1A
Given the part mix, process routings, and processing times for the three parts in Problem 19.1. The FMS planned for this part family will operate 250 days per year and the anticipated availability of the system is 90%. Determine how many servers at each station will be required to achieve an annual
Given the part mix, process routings, and processing times for the four parts in Problem 19.3. The FMS proposed to machine these parts will operate 20 hours per day, 250 days per year. Assume system availability = 95%. Determine(a) How many servers at each station will be required to achieve an
A FMS consists of three stations plus a load/unload station. Station 1 loads and unloads parts using two servers (material handling workers). Station 2 performs horizontal milling operations with two servers (identical CNC horizontal milling machines). Station 3 performs vertical milling operations
Solve Problem 19.3 except the number of carriers in the part handling system = 3.Problem 19.3A FMS consists of three stations plus a load/unload station. Station 1 loads and unloads parts using two servers (material handling workers). Station 2 performs horizontal milling operations with two
Suppose it is decided to increase the utilization of the two non-bottlenecks machining stations in the FMS of Problem 19.4 by introducing a new part, part E, into the part mix. If the new product will be produced at a rate of 2 units per hour, what would be the ideal process routing (sequence and
A semi automated flexible manufacturing cell is used to produce three products. The products are made by two automated processing stations followed by an assembly station. There is also a load/unload station. Material handling between stations in the FMC is accomplished by mechanized carts that
Use the extended bottleneck model to solve problem 19.1 with the following number of parts in the system:(a) N = 2 parts and(b) N = 4 parts.Also determine the manufacturing lead time for the two cases of N in (a) and (b).Problem 19.1A flexible manufacturing cell consists of two machining
Use the extended bottleneck model to solve problem 19.2 with the following number of parts in the system:(a) N = 3 parts and(b) N = 6 parts.Also determine the manufacturing lead time for the two cases of N in (a) and (b).Problem 19.2Solve Problem 19.1 except the number of servers at station 2 (CNC
Use the extended bottleneck model to solve problem 19.3 with the following number of parts in the system:(a) N = 5 parts,(b) N = 8 parts, and(c) N = 12 parts.Also determine the manufacturing lead time for the three cases of N in (a), (b), and (c).Problem 19.3A FMS consists of three stations plus a
What are the two aspects of quality in a manufactured product? List some of the product characteristics in each category.
What is a Pareto chart?
What is a defect concentration diagram?
What is a cause and effect diagram?
What is Six Sigma?
What are the general goals of Six Sigma?
Why does 6( in Six Sigma really mean 4.5(?
What is the define step in DMAIC? What is accomplished during the define step?
What are master black belts in the Six Sigma hierarchy?
Discuss the differences between the traditional view of quality control and the modern view.
What is a CTQ characteristic?
What is the measure step in DMAIC?
Why is defects per million (DPM) not necessarily the same as defects per million opportunities (DPMO)?
What is the analyze step in DMAIC?
What is root cause analysis?
What is the improve step in DMAIC?
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