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Mechanical Engineering
Date
Dec 6, 2023
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Instructions
review the Scenario – Cisco Metals
On January 3, 2018, following the Christmas production shutdown, there was a 2 day delay in
the start-up of a production line at Cisco Metals. Over the Christmas shutdown, there was
repair work happening on the furnaces in the facility. Thirty coils were being replaced in one of
the furnaces.
The delay cost 2 days of production at about $7000 per day. There were also 14 additional
people on each crew working around the clock because of the maintenance delay. This delay
was due to the maintenance staff not having the grinding wheels needed to cut this particular
coil from the furnace. The grinding wheels they had were #62 and they needed #62-2.
Maintenance had put in a request 4 weeks ago and received the wheels a week later, but did
not realize they had the incorrect grinding wheels until the job was started.
The purchasing department substituted #62 wheels for the #62-2 wheels that were originally
requested. They appeared to be the same wheel and the #62 wheels were $40 less than the
#62-2 grinding wheels. Purchasing regularly substitutes a less expensive part if it provides the
same function. In this case, the material was different between the two grinding wheels and
had been selected specifically for cutting the alloy that had been used in the furnace coils.
The #62 wheels cut much slower and kept breaking which was dangerous though no one had
been injured. The delay came from the slow cutting time, work stoppage, and waiting for the
original #62-2 wheels that were now being sent on an emergency basis.
2) Create a Cause-and-Effect Relationship Chart Start small using a basic linear flow. Then use questions
to fill in the details by adding causes horizontally and vertically to reflect additional information and/or
"necessary and sufficient logic".
Should contain, must have/follow these
The causes identified are sufficient to produce the associated effect
The causes identified in the map are necessary to produce the linked effects
Impacted goal is properly identified
Enough detail is provided in the map that the final causes are solved, they will prevent the issue.
Evidence of causes is provided where possible.
Leadership, ideas, and collaboration shown in MSTeams and/or participation in at least one meeting with
group
develop a diagram
a few seconds ago
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Helpful Assistant
Here is a cause-and-effect relationship chart for the scenario you provided:
The main impacted goal was to restart production at restart production at restart production at Cisco
Metals after the Christmas shutdown within the expected timeline.
The direct cause of the delay was the maintenance staff not having the correct (#62-2) grinding wheels
to remove the furnace coils. This prevented them from completing the repair work on time.
A necessary cause of the maintenance staff not having the correct wheels was that purchasing had
substituted the incorrect (#62) grinding wheels when fulfilling the original request.
A root cause of the incorrect substitution was that purchasing regularly substitutes less expensive parts
without verifying they provide the same function. In this case, the material composition was different
between the #62 and #62-2 wheels.
Some additional effects of not having the correct grinding wheels were:
The #62 wheels cut much slower, prolonging the repair work.
The #62 wheels kept breaking during use, requiring work stoppages to change wheels. This further
delayed completion.
Emergency ordering of the correct #62-2 wheels was required once the issue was discovered,
introducing additional delay.
The production line startup was delayed by 2 days, costing $7000 per day in lost revenue.
Additional crews of 14 people each had to work overtime due to the maintenance delay, increasing
costs.
Let me know if you need any part of the cause-and-effect relationship explained further or if you have
additional questions!
Your preview ends here
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Related Questions
Problem 3: A small gearing system in your brand-new 3D printer fails as you were printing,
leading to an overload in the motor and a fire in your home. The fire spreads, burning half of
Everglades National Park in the worst environmental disaster in US history.
The printer company blames you! Stating that you must have been misusing the printer some-
how. Use your engineering knowledge to "show those jerks you mean business!"
You investigate and find a serial number on the gears and type it into Google, finding the
company that manufactures the gears. Their website provides some info that this series of gear is
made from AISI 4340 steel and the yield strength is 125 kpsi.
Assuming each gear tooth acts as a small cantilever, prove to the 3D printer company that they
are liable for the fire.
oct
#
Gear Information
Gear radius (r): 1.00 in
Tooth length (1): 0.15 in
Tooth height (h): 0.15 in
Tooth thickness (b): 0.1 in
Angular velocity (w): 0.1 rad/s
Motor Information
Power (H): 0.009 hp
1…
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5 Look at the flow chart showing the steps of the design process. Then read the list of
steps for designing a thermos. These steps are not in order. Write the letter of each
step in the appropriate box of the flow chart.
The Design Process
Find a problem
Keep records
Plan and build
a prototype
Keep records
Test and
improve
Keep records
Communicate
the solution
arrow_forward
Instructions:
• Create a step by step and detailed explanation on how to solve the problem attached
below.
Create a script-like document like how you would explain this in a video presentation.
Explain every single step with full details.
Think of it that you have a youtube channel and you are explaining this problem step by
step and on this document you will put the transcript of your video presentation except
there is no video presentation only the transcript is needed.
• Include complete solution and what formulas are used.
PROBLEM:
Given is a thin-walled tube with the following data:
Wall thickness- 2mm
ABC is a sector with a radius of 100 mm
AOD & COD is a triangle
Torque is 800 N.m
Length of the thin walled tube is 2 m.
Use G=24 GPa for aluminium
B
30⁰
Determine the following:
a. Enclosed Area
b. Perimeter of the thin walled tube
c. Shear flow
d. Shear stress
e. Angle of twist
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Q1.
A power-shift crawler tractor is excavating hard materials of earth (clay) and pushing it a distance
of 100 ft. The hourly cost of a power-shift crawler tractor is $200. Maximum reverse speeds are:
first range, 6 mph; second range, 9 mph; and third range, 11 mph. Rated blade capacity is 18
LCY. Estimate dozer production if the job efficiency factor is 50 min/hr and what is the expected
unit cost for dozer work ($/BCY)?
arrow_forward
Task 3: In the context of maintenance costing, planning, and scheduling, clarify the following:
What are the general categories of potential maintenance costs? Please provide examples for each
category. Also, link this to the field trip you participated in at Al-Nabil factory and explain how these
costs are calculated.
Explain the practical meaning of the Work Order System for maintenance planning. Please discuss how
this approach is used at Al-Nabil Factory. Additionally, emphasize the importance of maintenance
planning and its impact on the overall productivity of the plant.
Clarify the maintenance inventory management system used at Al-Nabil factory? Please explain its
ultimate significance in terms of the factory's availability and overall maintenance costs.
Clarify the maintenance inventory management system adopted in Al-Nabil factory and its ultimate
significance in terms of factory's availability and the overall maintenance costs.
arrow_forward
Quesition no.2.5
arrow_forward
Discuss each element of the example plan provided and indicate benefits each section activity provides in helping to manage risk with the mechanical and electrical subcontractors on a project.
After reviewing the sample plan discuss the benefits of of the activities defined in the subsections that help manage risks with mechanical and electrical subcontractors.
Please be as detailed as possible
and thank you in advance for your help.
arrow_forward
The MPS start quantities for product A calls for the assembly department to begin final assembly accordingto the following schedule: 100 units in week 2; 200 units in week 4; 120 units in week 6; 180 units in week 7;and 60 units in week 8. Develop a material requirements plan for the next 8 weeks for items B, C, and D.The BOM for A is shown in Figure 11.26, and data from the inventory records are shown in Table 11.4.
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The BOM for product A is shown in Figure 11.40, and datafrom the inventory records are shown in Table 11.9. In theMPS for product A, the MPS start row has 100 units in week 3and 200 in week 6. Develop the material requirements planfor the next 6 weeks for items C, D, and E.a. Develop the material requirements plan for the next6 weeks for items C, D, and E.b. What specific managerial actions are required inweek 1?
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Please solve as many you can. Thank you sir
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1. A certain batch of parts is routed through six machines in a batch production plant. The setup and operation times for each machine are given in the table below. Batch size is 200 and the average nonoperation time per machine is15 hr. Determine (a) manufacturing lead time and (b) hourly production rate for operation 4.Machine 1 2 3 4 5 6Setup time (hr) 5 3 6 4 5 3Operation time (min) 3.0 3.3 8.2 3.9 4.5 2.3
a. 6(4.3+200(3.9/60)+15) = 193.8 hours 24.2 days if 8 hour shiftb. 4(60)+200(3.9)/200 =5.1 hourly production for operation 4
2. Suppose the part in the previous problem is made in very large quantities on a production line in which an automated work handling system is used to transfer parts between machines. Transfer time between stations is 30 sec. total time required to setup the entire line is 102 hr. Assume that the operation times at the individual machines remain the same as in the previous problem, Determine (a) manufacturing lead time for a part coming off the line,…
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A batch of 35 parts is ordered by a customer about every six months. The parts are currently processed sequentially through five conventional machines, listed in the following table with setup times and work cycle times per piece. These machines all require an operator to be in attendance during the work cycle. There is a delay of 10 hr/machine dueto transport between machines and waiting in queues of other parts processed by thesemachines. A recommendation has been made to process the parts on a new multitaskingmachine that would complete the batch in one setup, which would involve a simple fixtureand a setup time of 2.0 hr. The work cycle on the multitasking machine consists of thesame operations that are accomplished by the five machines, but the cycle time would beless than the sum of the five cycle times by one-half because of tool path improvementsand reduced part handling. Determine the manufacturing lead time (how long it takes tocomplete the batch of 35 parts, including…
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Procedure:
1. Copy the following table on a separate sheet of paper.
2. List all knowns
3. List all unknowns
4. List all equations that you need to use
5. Draw a diagram of the problem
6. Substitute and solve the problem. Be sure to show your work (1pt).
7. Final Answer
8. Take a picture and upload your answer!
Problem:
A 25 ft long solid steel rod is subjected to a load of 10,000 lb. This load causes the rod to stretch
0.477 in. The modulus of elasticity of the steel is 30,000,000 psi. Determine the diameter of the rod.
(precision of 0.00)
Table:
#1
Substitute and Solve:
Knowns:
Draw:
Unknowns:
Equation:
Final Solution
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|Read the problem statement and the solution provided. There may or may not be one or more
mistakes in the solution. Go through the solution carefully and then do the following.
1. State if the solution is correct or incorrect
2. If the solution is incorrect, identify what is the mistake in the solution. Be specific and succinct.
3. If the solution is incorrect, provide the final solution with appropriate steps. You can make the
corrections directly on a copy of this provided solution, but make sure you clearly explain the
corrections.
Problem: Consider fully-developed flow of water through a 24-cm diameter tube. The water comes in at
20°C and exits at 40°C. The surface temperature of the tube is uniform at 60°C. The water flow has a
mass flow rate of 0.24 kg/s. What is the average convection coefficient of the water flow?
Solution: We have T, = 60°C, Tmi = 20°C, Tmo = 40°C, So, the bulk-mean temperature is Tm = 30°C.
The appropriate properties are: u = 7.98 × 10-4 kg/ms;
k = 0.615…
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B: Iraq Glass Industries Company produces two types of products, A and B,
each one goes through two production stages. Product A needs 1 working hour
in the first phase, and 4 working hours in the second phase, while Product B
needs 2 working hours in the first phase, and 3 hours of work in the second
stage. If you know that the profit per unit of product A is $60, and the profit
per unit of product B is $50. The available weekly working hours in the first
stage are 40 hours, and in the second stage are 120 hours.
Required: Building a mathematical model that maximizes the company's
profits
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Answer the two connected questions (Task A-1 and A-2). Provided in the last part are the guides and examples:
The process for large-scale manufacture of paper has been largely unchanged for the last 125 years. The pulp and paper industry today is highly capital intensive, and there is an ongoing drive towards process integration, thereby increasing the efficiency of utilization of available process resources. This paper deals with the Kraft process (see Fig. 1) though the general principles described can be extended to other pulping processes. As shown in Figure 1, five water sinks and four water sources are considered for in-plant water reuse/ recycle. Prior to water reuse/ recycle, the network requires a freshwater flow rate of 36,400 tonne/day and generates 37,186 tonne/day of wastewater (sum of the individual sink and source flow rates in Table 1). The freshwater source that is available for service has an impurity concentration (chloride content) of 4.2 ppm, which is higher than…
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time study data. The production process must follow a specific route of
processes A, B, C, and D respectively. Task A is in full automatic mode and
requires one operator at the workstation. The worker at task B was rated with
90%, the worker at task C was rated with 115% and the worker at task D was
rated with 80%. The standard allowances accepted by the company are 6% for
fatigue, 5% for personal, and 4% for delay. The normal operating period is 8
hours per day and 24 days per month. Analyse the given information and
determine the standard time for the product in minutes.
Table 3: Average Processing Time (minutes)
Job
Description
Average
Processing Time
A
Automatic
B
Manual
40
C
Manual
30
D
Manual
35
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You are given a line balancing problem with
the following diagram. The processing time is
above each process. Using the ranked
positional weight (RPW) heuristic calculate the
number of workstations for a desired cycle time
CTd
= 11 and the line efficiency based on this
heuristic.
B
5
7
A
D
E
F
4
6.
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Q 5:
Suppose you are patenting a mechanical component that you have designed. Which type of patent you will be applying for and what will be the main outlook of the patent application?
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A robot is used for loading and unloading of parts to automated flexible machines. Loading
time is 1 minute; unloading time is 1.5 minutes; machining time 15 minutes; Robot travel time
between the machines including the inspection time is 3 minutes. Cost of robot C,=30 TL/Hour;
cost of machines C2=40 TL/Hour. How many machines (integer number) should be assigned
to the robot so that the total robot and machine costs per cycle are minimized?
8 -
176
a)
4
b)
3
c)
2
d)
e)
6.
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1. You are a mechanical engineer at one of the oil and gas company and you face this technical problem
inside plant:
a broken chain issue that frequently occured on a machine lately. Obviously this issue causes
production activity stopped temporarily and production loss.This broken chain issue occured
since about three months ago after we replaced the electric motor into the bigger one, it's
about 2.2 KW or 3 hp. As an engineer in this department, You responsible to stop this broken
chain happened on and on. So, make a calculation to find out the optimum specification of
chain sprocket thru theoritical approach based on Machine Design.
Motor Power (P) = 3HP 2.2 KW = 2337 Nm/s
ni = 952 Rpm : speed of rotation od smaller spracket in rpm
n2 = 600 Rpm : speed of rotation od larger spracket in rpm
N1 = 17: Number of teeth on the smaller sprocket
N2 = 27 : Number of teeth on the larger sprocket
D1 = 44 mm : Ptich circle diameter of the small sprocket
D2 = 74 mm : Ptich circle diameter of the…
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Complete solution. Thanks
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Kasapreku Distilleries Ghana Ltd, a liquor Production Company located in Ghana had a major contract to supply alcoholic beverage to a neighboring country within one week deadline. In the course of production, there was a major breakdown which led to a long downtime resulting in missing out on the deadline. Kasapreku had lost a great deal of money due to the company’s inability to seriously inculcate safety and maintenance engineering in their system.
(a) Discuss the importance of safety in an engineering maintenance from Kasapreku’s case scenario
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A company uses various machines in the preparation of ice cream. The firm has been successful until recently when it noticed growing repair expenses for the various machines it uses. Over the past 20 months, the machines have broken down at the rate indicated in the following table:
Each time a machine breaksdown, the company estimates that it loses an average of US$300 in production time and service expenses. Should the company opt to purchase a service contract for preventive maintenance by Angeles Machineries Inc., (AMI) there will still be breakdowns, averaging one breakdown per month. The price for this service by AMI is US$150 per month.
a. If the company continues as is, what is the expected no. of breakdowns based on past history?
b. What will be the cost of breakdowns per month to the company without a preventive maintenance contract?
c. What will be the cost of breakdowns per month to the company with a preventive maintenance contract?
d. Should they engage the…
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Please solve the question on the sheet and get a clear picture and submit the picture.
thankyou
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Please do not copy other's work and do not use ChatGPT or Gpt4,i will be very very very appreciate!!!
Thanks a lot!!!!!
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A certain Batch manufacturing plant requires one operator to tend to 2 semiautomatic
machines used in production. The plant operates one 10-hour shift per day for 250 days
in a year. The operator is paid $30 per hour with applicable factory labor overhead rate
of 50%. Other pertinent information about the system in include the information
provided below. Determine the hourly cost of the system.
Machine 1
Machine 2
Initial cost
$125,000
$10,000
$5000
$150,000
$5000
$3000
Installation
Yearly maintenance cost
10 years
$5000
SL
years
$10,000
SV
20%
20%
ROR
50%
Applicable MOHR
30%
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True, False or Uncertain. Explain your answer.
Own wage elasticity JELLlincrease if product demand elasticity n? is high.
In short run, when there is an increase in wage rate, each firm will hire less labor
and so the industry labor demand is simply the horizontal summation of firm's
labor demand.
а.
b.
Labor demand is represented by the marginal revenue produce schedule (MRP)
when we have competitive product market while it will be represented by the
value of marginal product schedule (VMP) when we have a product market
monopolist.
When elasticity of substitution, SLK, increase that means the L and K are less
substitutable, and the isoquant will be L-shaped.
Minimum wage imposed by the government is always bad for the economy
because it increase unemployment and deadweight loss.
с.
d.
e.
3.
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I asked for problems 6 and 7 to be answered, but I did not get a properly structured answered as the example shows on problem number 1. Here is the link to the questions I already had answered, could you please rewrite the answer so its properly answered as the example shows (Problem 1)?
https://www.bartleby.com/questions-and-answers/it-vivch-print-reading-for-industry-228-class-date-name-review-activity-112-for-each-local-note-or-c/cadc3f7b-2c2f-4471-842b-5a84bf505857
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Create me a simplified cash flow diagram for the project starting from initial development until the first month of profit. (The second photo is the template for cash flow diagram, please follow closely.)
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14.15 ANSWER A AND B
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