Question: 4 . A semi - automated assembly machine, assembles and welds automotive components for a single shift of 7 . 5 hours, 5 days a

4. A semi-automated assembly machine, assembles and welds automotive components for a single shift of 7.5 hours, 5 days a week; planned throughput =150 units/hour; actual output =2875 units/week. The following losses are encountered during assembly:i.Incorrect assembly causes the machine to stop and needs re-set on average 5 times/hr. where 1 unit and 2 minutes are lost. (This leads to performance loss due to minor stoppage and also quality lossii.Worn out electrodes are to be replaced once per week, it takes 1 hour when 30 units are scrapped => availability and quality losses iii.Burst out cooling hose causes a machine breakdown once in a month and replacement takes 5 hours => availability lossiv.Misaligned fixture causes a loss of 220 units/ week => quality lossv.For different size parts, fixtures to be removed and replaced and electrode position to be adjusted 3 times/week which takes 2.25 hours where 24 units are scrapped each time => availability and quality lossesvi.Actuating cylinder sometimes sticks for 30 minutes/ady causing production delay which takes double cycle time => performance lossvii.Application of rust protective spray by operator stopping the machine at the start and end of the day takes 5 minutes each time => minor stoppages thereby performance loss viii.Limit switches corrode once in every 6 weeks stopping the machine and replacement takes 6 hours => availability loss.Calculate the OEE.

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