A certain job shop specializes in one-of-a-kind orders dealing with parts of medium-to-high complexity. A typical part is processed sequentially through ten machines in batch sizes of one. The shop contains a total of eight conventional machine tools and operates 40 hours per week of production time. Average time values on each part per machine are: Machining time = 0.5 hour; Work handling time = 0.3 hour; Tool change time = 0.2 hour; Setup time = 3 hours; Nonoperation time = 12 hours. A new programmable machine is being considered that can perform all ten operations in a single setup. The programming of the machine for this part will require 20 hours; however, the programming can be done off-line, without tying up the machine. Setup time will be just 2 hours because simpler fixtures will be used. Total machining time will be reduced to 80% of its previous value due to advanced tool control algorithms; work handling time will be the same as for one machine; and total tool change time will be reduced by 50% because tools will be changed automatically under program control. For the one machine, nonoperation time is expected to be 12 hours, same as for each conventional machine.   (a)Determine the manufacturing lead time for the conventional machines and for the new programmable machine (b)Determine the plant capacity for: (i) a job shop containing the eight traditional machines, and (ii) a job shop containing two of the new programmable machines. Assume both alternatives operate at full capacity. (c)Determine average work-in-process for (i) and (ii) in (b). Use the data given above.

Question

A certain job shop specializes in one-of-a-kind orders dealing with parts of medium-to-high complexity. A typical part is processed sequentially through ten machines in batch sizes of one. The shop contains a total of eight conventional machine tools and operates 40 hours per week of production time. Average time values on each part per machine are: Machining time = 0.5 hour; Work handling time = 0.3 hour; Tool change time = 0.2 hour; Setup time = 3 hours; Nonoperation time = 12 hours. A new programmable machine is being considered that can perform all ten operations in a single setup. The programming of the machine for this part will require 20 hours; however, the programming can be done off-line, without tying up the machine. Setup time will be just 2 hours because simpler fixtures will be used. Total machining time will be reduced to 80% of its previous value due to advanced tool control algorithms; work handling time will be the same as for one machine; and total tool change time will be reduced by 50% because tools will be changed automatically under program control. For the one machine, nonoperation time is expected to be 12 hours, same as for each conventional machine.

 

(a)Determine the manufacturing lead time for the conventional machines and for the new programmable machine

(b)Determine the plant capacity for: (i) a job shop containing the eight traditional machines, and (ii) a job shop containing two of the new programmable machines. Assume both alternatives operate at full capacity.

(c)Determine average work-in-process for (i) and (ii) in (b). Use the data given above. 

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