Question: 4 . 1 A manufacturing company is evaluating replacing a manual material transfer operation with an industrial robot. The current manual operation involves a human
A manufacturing company is evaluating replacing a manual material transfer operation with an industrial robot. The current manual operation involves a human worker transferring parts from a conveyor to a pallet, following a specific pattern palletizing Current Manual Operation: Worker picks part from conveyor, moves to pallet, places part: seconds per part. Worker takes a minute break midmorning and midafternoon, plus a minute lunch break. Assume an hour shift, with the last minutes nonproductive for cleanup. The worker can only palletize one part at a time. Proposed Robotic Operation: A robot will perform the palletizing task. The robot's cycle time to pick a part and place it on the pallet varies depending on the location on the pallet. The average robot cycle time is seconds per part. The robot system has an uptime efficiency of due to random malfunctions. Downtime results in zero production. Programming the robot and setting up the pallet fixture for a new product style takes minutes. Production runs are typically parts. Calculate the average production time per part for the manual operation over an hour shift, accounting for breaks and cleanup. Assume constant work speed when not on break. Calculate the production rate in parts per hour for the manual operation over an hour shift. Calculate the average production time per part for the robotic operation, accounting for setup time and the production quantity. Calculate the production rate in parts per hour for the robotic operation, accounting for the uptime efficiency and setup time over the production run. Based only on the operational characteristics provided cycle time, downtimes, etc. and without considering direct costs yet, analyze the potential benefits and drawbacks of switching to the robotic system for these mediumsized batches. Reference specific concepts like cycle time reduction, nonproductive time setup vs downtime repeatability implied benefit for consistent pallet pattern and the characteristic of a repetitive work cycle. Briefly mention how the cost of the robot system would need to be factored into a full economic justification, referencing the concept of higher investment cost as a potential disadvantage compared to manual operations.
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