IE 307 Work Systems Analysis & Design HW 5  

9.4 A supplier of machined components for industrial machinery (e.g., power tools, pumps, motors, compressors) operates a factory that includes a forge shop, machine shop, and finishing department. Many of the parts produced by the company are fabricated through these three departments. Because of this, the factory is laid out as three large square rooms, arranged in-line to form a rectangle with an aspect ratio of three-to-one. Each room is 200 ft. by 200 ft. The rectangle runs from north to south, with the forge shop on the south end and the finishing department on the north end. Large doors are located on the south wall for work entering the factory and on the north wall for finished products exiting the factory. For one part of particular interest here, the raw material is a steel billet that is purchased from a steel wholesale supplier. The billets arrive in pallet loads of 100 billets at the shipping and receiving department, which is a building that is 35 ft. by 50 ft. located 25 ft. from the south wall door of the factory. The shipping and receiving department inspects the parts and sends them by forklift truck to be stored in the company’s warehouse that is located in another building 500 ft. away from the factory in a southerly direction. The warehouse is 200 ft. by 200 ft. with its entrance door on the north wall. When a production order for the part is received, a factory forklift truck is dispatched to the warehouse to retrieve the billets. The forklift truck must wait while the warehouse crew locates the billets in storage, takes a pallet out of storage using the same type of forklift truck, and delivers the pallet to the dock where it is transferred to the factory forklift. The pallet is then brought back to the factory and delivered to the forge shop. The billets must wait their turn in the production schedule before being pressed into the desired shape by one of the forge presses. From the forge shop, the parts are moved to the machine shop where they are machined on two different machine tools, a milling machine and a drill press. From the machine shop, the parts travel to the finishing department for painting and baking (to cure the paint). From the finishing department, the parts are moved back to the machine shop, where additional milling is accomplished to provide two machined metal surfaces that will mate with other components in the final product. The parts are then moved to the shipping and receiving department for shipment to the customer. (a) Develop the flow process chart and (b) flow diagram for the process, using the centroid of each department to estimate distances between departments. (c) Based on your flow process chart, what are some changes in the production process that you would recommend? (d) Develop a revised procedure for the production process, documenting your revision in the form of a new flow process chart.

Question: 03

A worker work in a semi hydraulic juicer shown in the figure below.  The worker loads the juicer with the fruit in the loader hopper and start the juicer which automatically run in its own.  The juice is collected through the dispenser in a bucket.  The operator collects the juice and place a label on the bucket and clean the waste in the waste bin and carry the bucket to quality control station. After finishing the quality control, the operator takes the juice to a final packaging station and come back to the juicer for a second run. The time for all the activities is given in the table below.  For safety regulations, the juicer can’t be run during loading and cleaning operations.

1. Draw the machine operator chart with the lowest cycle time.
2. Determine the percentage of the idle time for the operator and the juicer

Question: 04

9.8 Refer to right hand/left hand activity chart presented in the notes for the pegboard placement task shown below (a) If the workplace were redesigned using a work holding fixture, and the worker were trained to use both hands simultaneously to perform the task (see the table below for the revised task and time), construct a right-hand/left-hand activity chart for the revised method, estimating the amounts of time for each step in the method. (b) What is the percent reduction in cycle time?

Question: 05

An assembly product is made of 7 parts.  Each part undergoes different operations then assembled.  Table below shows the operations for each part, the material and whether it is purchased.  Bushing and Stem are assembled to form (sub-assy-1) then attached to the Body part. The Stem and Fiber Packing parts are assembled to form (sub-assy-2) and then attached to sub-assy-1.  Finally the Handle and the Nut are attached to the assembly.  Draw the operations chart of the product