DEPARTMENT OF INDUSTRIAL ENGINEERING TECHNOLOGY

MANUFACTURING SYSTEMS DESIGN

MFDMIA2

TEST I
TIME - 2hrs 09/03/2020

Answer all questions

QUESTION 1

1.1 Discuss the key functions of a manufacturing system? (2)

1.2 Discuss the four components of a manufacturing system. (4)

1.3 A computer system is an integral component in a modern manufacturing system. Discuss

any four functions of the computer system. (4)

[10]

QUESTION 2

2.1 A total of 6,500 body panels must be produced in the press department in three (3) days.
Manually operated presses will be used to do the job and the cycle time is 31 secs. Each
press must be set up before production starts and the set-up time is 3.0hr. How many
presses and operators must be installed to satisfy demand? Assume 7.5 hours available time
per day? (4)

2.2 A new forging plant must supply parts to the automotive industry. Because forging is a hot
operation, the plant will operate 24 hr per day, five days per week, 50 weeks per year. Total
output from the plant must be 12,000,000 forgings per year in batches of 1350 parts per
 batch. Anticipated scrap rate is 4%. Each forging cell will consist of a furnace to heat the
parts, a forging press, and a trim press. Parts are placed in the furnace an hour prior to
forging; they are then removed and forged and trimmed one at a time. On average the
forging and trimming cycle takes 0.7 min to complete one part. Each time a new batch is
started, the forging cell must be changed over, which consists of changing the forging and
trimming dies for the next part style. It takes 3.0hr on average to complete a change-over
between batches. Each cell is considered to be 97% reliable during operation and 100%
reliable during changeover. Determine the number of forging cells that will be required in
the new plant. (10)

2.3 A machine operator is assigned two machines in a machine cell. The service time per
machine is 0.40 min and the time to walk between machines is 0.20 min. the machine
automatic cycle time is 2.0 min. if the worker’s hourly rate is R10/hr and the hourly rate for
each machine is R25/hr. Calculate:

a) The hourly operating cost for the cell (2)

b) The unit production cost, assuming two units are produced by each machine during
each machine cycle (6)
c) What is the percentage idle time of the workers? (2)
d) Determine the maximum number of machines that should be allocate in each machine
cell, in order to achieve the lowest production cost (10)

[34]

QUESTION 3

An Industrial Engineer has been assigned to design a single model assembly line to
produce 400 000 electric jugs per annum. The assembly line will operate 8hr /shifts, five
shifts per week, 50 weeks per annum. Total work content time is 35 mins. Line
availability is estimated at 95%. Determine:
a) Cycle time, Tc (3)
b) Theoretical minimum number of workers on the line (3)

[6]

TOTAL 50