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