Computer Integrated Manufacturing

Module 1 – Assignment 1

1. The average parts produced in a certain batch manufacturing plant must be processed through
an average of 6 machines. There are 20 new batches of parts launched each week. Average
operation time is 6 mins, average setup time is 5 hrs., average batch size is 25 parts and average
non-operation time per batch is 10 hrs. per machine. There are 18 machines in the plant.
The plant operates on an average of 70 production hrs. per week. Scrap rate is negligible.
Determine
a. Manufacturing lead time for an average part
b. Plant capacity
c. Plant Utilization

2. In a manufacturing plant a part is produced in a batch size of 60 units. The batch must be routed
through 8 operations to complete it. Average setup time is 5 hrs. per operation and average
operation time is 10 mins. Average non-operation time is 7 hrs. per operation. Determine
a. Manufacturing lead time in number of days of the plant which runs 8hrs. shift per day
b. Production rate of the plant

3. A manufacturing plant produces gas cylinders in a batch size of 60 units and requires a sequence
of 8 operations in the plant. The average set up time is 3 hrs. and average operation time per
machine is 8 mins. Average non-operation time hrs. How many days it will take to produce a
batch, assuming the plant operates on a 7 hrs. shift per day basis.

4. A ten station transfer machine has an ideal cycle time of 30 secs. The frequency of line stops,
F= 0.75 stops per cycle. When a line stop occurs the average down time is 4 mins. The cost of
raw work part is Rs 0.55 per piece, line operating cost is Rs 42 per hour and cost of disposal
tooling is Rs 0.27 per piece. Determine
a. Average production rate in piece per hour
b. Line efficiency
c. Proportion down time
d. The average cost of work piece produced

5. An eight station transfer line is used to produce a component in a motor which is currently
produced by conventional methods. The manufacturing department has established the ideal
cycle time as 1.2 mins. The frequency of breakdowns are 0.1 stops / cycle and average down
time per stop is 7 mins. The scrap rate for the current conventional processing method is 5%.
The starting cost of the component is Rs 1.5 and it will cost Rs 45 / hour to operate the line. The
cost of cutting tools is Rs 0.15 / work part. Determine the production rate, number of hrs. to
meet the demand of 2000 units / week, line efficiency, balance delay and cost / unit produced.
Note: Production Rate = (1/Tp) * scrap %
6. The ideal cycle time of a 16 station transfer line is 1.4 mins. The average down time per line will
be 6 mins and the probability of break downs per cycle is equal for all cycles and is equal to
0.004. Determine production rate and line efficiency by considering both upper bound and
lower bound approaches.

7. In the operation of a 15 station transfer line the ideal cycle time is 0.5 mins. Break down occurs
at the rate of once in every 20 cycles and the average down time per break down is 9 mins. The
transfer line is located in the plant that works for 8 hrs. a day and 5 days a week. Determine
a. Line efficiency
b. How many parts the transfer line will produce in a week

Note: F = 1/No of Cycles

8. A 24 station transfer line has an ideal cycle time of 0.7 mins, an average down time is 6 mins. Per
line stop occurrence and station failure frequency of 0.01 for all stations. A proposal has been
submitted to locate a storage buffer between stations 12 and 13 to improve the efficiency.
Using upper bound approach determine the current line efficiency and the production rate. Also
determine the maximum possible line efficiency and production rate that would result from
installing a storage buffer