Question

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1. A company has five machines (1 lathe, 2 mills and 2 drills) arranged sequentially to produce a batch of 200 parts. The following table lists the setup and work cycle times per piece for the five machines. Delay (hr) 10 10 10 10 10 Work cycle time (min) 15 27 12 Setup time (hr.) 2.50 1.25 1.50 0.50 0.75 Machine 1. Lathe 2. Milling (V) 3. Milling (H) 4. Drill (i) 5. Drill (ii) Management wants to procure a multitasking machine to replace the five machines. This new machine would complete the batch of 200 in one setup. The setup time would be 2 hours and the delay would be 10 hours (a) The manufacturing lead-time (how long it takes to complete the batch of 100 parts, for the multitasking machine. Determine: including delays) for the five conventional machines and (b) The manufacturing lead-time for the multipurpose machine.

Answer 1

(a) The manufacturing lead time for conventional set up of machines

set up time for each step + work cycle time x number of units + delay for each machine

Case I - If the batch of 200 parts is produced in one go.

Set up time = 6.5 hours.

Processing time = 200 x ( 15+27+12+7+9) = 200x70 = 14000 min = 14000/60 hours = 233.33 hours

Delay = 5x10 =50 hours

Total manufacturing lead time = 6.5+233.33+50 = 289.83 hours

Case II -If the work is done in 2 batches of 100 each. time taken to produce each batch

Set up time = 6.5 hours

Processing time = 116.66 hours

Delay time = 50 hours

Total time = 173.16 hours to produce each batch

(b) Manu. Lead time for single machine when 200 parts are produced in one go

2+233.33 + 10 = 245.33 hours