ME20B092 Assignment-1

The document discusses the production of multiple products and machines. It provides details on the number of components, processing times, machine utilization rates, and calculations to estimate manufacturing lead times and work in progress. Specifically, it calculates: 1) The total number of components needed for different products and models 2) Processing times and number of operations for components 3) Average cycle times and batch times for different production runs 4) Utilization rates for different machines 5) Equations to estimate manufacturing lead times and work in progress levels based on production rates, utilization rates, and number of stations.

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ME20B092 Assignment-1

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Assignment -1

Karteek Kashyap
ME20B092
1) Product- A, 3600 units 48 components
40% made in plant, 60% purchased
Total no.of components = 3600*48 =172800
a) components purchased in plant equal to 0.4 * 172800
b) components purchased equal to 0.6 * 172800

Product- B: 2500 units 52 components

30% made in plant, 70% purchased

Total number of comprehensive equal to 52 * 2500

a) components in plant is equal to 0.3 * 130000

b) conference purchase design equal to 0.7 *130000

total components purchase is equal to 194680

total comprehensive made in plant is equal to 108120

2) 8 different models
Each model 900 units each product 180 components
6 processing operations 1 minute for each
a) Total number of components is equal to 8 * 900 * 180 = 1296000
b) Number of operations is equal to 1296000 * 6 = 7776000
c) Time for operation is equal to 7776000 minutes/year = 129600 hr/yr

3) Machine setup time is equal to 3 hours

processing time is equal to 1.6 minutes/cycle
2 parts produced in each cycle
Total handling time is equal to 0
What handling time is equal to 45 seconds
Close starting work units from tray, loading to machine each tray 24 units
Irregular work element 3 minutes
Batch quantity = 2400 units
a) Average cycle time
Processing time is equal to 1.8 * 2400/2 = 1920 min
Time for handling is equal to 45/60 * 2400/30 = 900 minutes
Time for irregular work is equal to 3 * 2400/24 =300 minutes
Average cycle time is equal to (1920 + 900 + 300 )/ 2400 = 13 min/unit
b) Batch time = Tsu + Q*Tc = 3 * 60 + 2400 * 1.3 = 180 +3120 =3300 min
c) T=Tb/Q =3300/2400 = 11/8 = 1.375 min/unit
Avg production rate = 1/Tp =1/13.75 = 0.727 parts/min
=43.63 units/hr
Assignment -1
Karteek Kashyap
ME20B092

4) 3 machines
40 hrs/wk
5 batches through 3 machines
F1a = 15/40 = 3/8
F2a = 10/40 =1/4
F3a = 8/40 =1/5

F2b=14/40=7/20
F3b=21/40
F2c=21/40
F1d=5/40 = 1/8
F2d=4/40 = 1/10
F2e=5/40= 1/8
F3e=5/40 = 1/5

5) Based on the given data,

Showing the calculations for sample part A,

1) In the above table the manufacturing lead time and work in progress for sample
5 parts set has been estimated.

Production rate is equal to 60 /cycle time =60/9.3 =6.45 units/hr

Utilization = (total working hours - non-operational hours)/ total working hours = 0.71

Leadtime= 1/R* (a^(sqrt(2*no.of stations +1)/(1-a)),

a=utilization , R = flow rate or production rate

= 1/6.45 *0.71^(sqrt(2(6+1))/(1-0.71) =0.15or 9.09 minutes

Work in progress = production rate= leadtime = 6.45 * 0.15 = 1 unit

Part B)

In the planned utilization becomes 100% then only during setup time the machine will be
operational then accordingly the calculated values are,
Assignment -1
Karteek Kashyap
ME20B092

Net utilization = (Total working hours - set up time)/ total working hours = (40-5)/40 = 0.88
for Part A

Plant capacity = Leadtime from table 1 has to be considered for calculation using the same
governing equations used for estimating Leadtime