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Cellular Mfg-3e-S 7-19, 21/06, 06/05/07 18.11 What are the four common GT cell configurations, as identified in the text? Answer: The four GT cell configurations listed in the text are (1) single machine cell, (2) group machine cell with manual handling, (3) group machine cell with semi-integrated handling, and (4) flexible manufacturing cell or flexible manufacturing system. 18.12 What is the key machine concept in cellular manufacturing? Answer: The key machine concept acknowledges that there is typically a certain machine in a cell that is more expensive to operate than the other machines or that performs certain critical operations. This machine is referred to as the key machine. It is important that the utilization of this key machine be high, even if it means that the other machines in the cell have relatively low utilizations. The other machines are referred to as supporting machines, and they should be organized in the cell to keep the key machine busy. 18.13 What is the difference between a virtual machine cell and a formal machine cell? Answer: Virtual machine cells involve the creation of part families and the dedication of equipment to the manufacture of these part families, but without the physical rearrangement of machines into formal cells. The machines in the virtual cell remain in their original locations in the factory. Formal machine cells represent the conventional GT approach in which a group of dissimilar machines are physically relocated into a cell that is dedicated to the production of one or a limited set of part. 18.14 What is the principal application of group technology in product design? Answer: As indicated in the text, the principal application of GT in design is to implement a design retrieval system that reduces part proliferation. 18.15 What is the application of the rank order clustering? Answer: The application of the rank order clustering in GT is grouping machines into cells based on the partmachine incidence matrix, which in turn is based on route sheets.
Develop the form code (first five digits) in the Opitz System for the part illustrated in Figure P18.2. Solution: L/D = 2.5/1.5 = 1.667 External shape = stepped, one hole Internal shape = smooth hole Plane surface machining = none Auxiliary holes, etc., = none Digit 1 = 1 Digit 2 = 1 Digit 3 = 1 Digit 4 = 0 Digit 5 = 0
18.3
Develop the form code (first five digits) in the Opitz System for the part illustrated in Figure P18.3. Solution: L/D = 121/36 = 3.361 External shape = stepped both ends with functional groove Internal shape = no hole Plane surface machining = none Auxiliary holes and gear teeth = spur gear. Digit 1 = 2 Digit 2 = 6 Digit 3 = 0 Digit 4 = 0 Digit 5 = 6
Cellular Mfg-3e-S 7-19, 21/06, 06/05/07 Machines 1 2 3 4 5 Solution: A 1 1 1 1 1 B 1 1 Step 1 C D E 1 Rank 2 4 1 3 5 A 1 1 B Step 2 C D 1 E A 1 1 1 1 1 B 1 1 C D E 1
1 2 3 4 5
3 1 4 2 5 Rank
1 1 1 3
1 1 4 Step 4 B 1 2 5
3 1 4 2 5
A 1 1
D 1
Step 3 B
1 1 1
1 1
Rank 1 2 4 5 3
3 1 5 4 2
A 1 1
D 1 1
1 1
1 1
Part families and machine groups: I = (A, D) and (3,1,5), II = (B, C, E) and (4, 2). 18.5 Apply the rank order clustering technique to the part-machine incidence matrix in the following table to identify logical part families and machine groups. Parts are identified by letters, and machines are identified numerically. Parts Machines 1 2 3 4 5 6 Solution: A 1 1 B Step 1 C D 1 1 1 1 1 1 1 1 1 E 1 F 1 Rank 2 6 1 5 3 4 A 1 1 B 1 1 1 1 1 2 5 1 1 1 4 Step 2 C D E 1 1 1 1 6 F A 1 1 B C D 1 1 1 1 1 1 1 1 1 E 1 F 1
1 2 3 4 5 6
3 1 5 6 4 2 Rank
3 1 5
A 1 1
B 1 1
Step 3 E D 1 1
Rank 1 2 3 148
Part families and machine groups: I = (A, B, E) and (3, 1, 5) II = (D, C, F) and (6, 4, 2)
Apply the rank order clustering technique to the part-machine incidence matrix in the following table to identify logical part families and machine groups. Parts are identified by letters, and machines are identified numerically. Machines 1 2 3 4 5 6 7 8 Solution: A 1 1 2 3 4 5 6 7 1 8 B 1 1 1 1 1 1 1 1 1 1 1 1 1 C D Step 1 E F G 1 1 H I 1 Rank 2 4 5 3 7 8 1 6 A 7 1 1 1 4 2 3 8 5 6 Rank 1 B C D 1 Step 2 E F G H I 1 1 1 1 1 1 5 7 2 1 1 1 6 1 4 1 1 1 1 1 8 9 3 A 1 B 1 1 1 1 1 1 1 1 1 1 1 1 1 1 C D Parts E F G 1 1 H I 1
A 7 1 1 1 4 2 3 8 5 6
D 1
I 1
Step 3 B F
1 1
1 1
1 1 1 1 1 1 1 1
Rank 1 2 3 4 6 7 8 5
A 7 1 1 1 4 2 6 3 8 5 Rank 1
D 1
I 1
Step 4 B F
1 1 1
1 1
1 1 1 1 1 7 1 1 8 1 1 9
I = (A, D, I) and (7, 1) II = (G, B, F) and (4, 2, 6) III = (C, E, H) and (3, 8, 5)
18.7
Apply the rank order clustering technique to the part-machine incidence matrix in the following table to identify logical part families and machine groups. Parts are identified by letters, and machines are identified numerically. Machines 1 2 3 4 A 1 1 B 1 1 1 1 C 1 D 1 Parts E 1 F G 1 1 H 1 1 I 1
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4 2 7 8 6 1 5 3 Rank
4 2 7 8 6 1 5 3
A 1 1 1
B 1 1 1 1
D 1 1
H 1 1 1
Step 3 I G 1 1 1 1
1 1 1 1 1 1 1 1 1
Rank 1 2 3 4 5 7 8 6
4 2 7 8 6 1 3 5 Rank
A 1 1 1
B 1 1 1 1
D 1 1
H 1 1 1
Step 4 I G 1 1 1 1
1 1 1 1 1 5 6 1 7 1 8 1 9 1
I = (A, B, D, H, I) and (4, 2, 7, 8, 6) II = (G, C, F, E) and (1, 3, 5) Note: packs G, C, and F in group I require processing in machine group II (machines 2, 7, and 8), and packs D and H require processing in machine group I (machines 1 and 3). 18.8 The following table lists the weekly quantities and routings of ten parts that are being considered for cellular manufacturing in a machine shop. Parts are identified by letters and machines are identified numerically. For the data given, (a) develop the part-machine incidence matrix, and (b) apply the rank order clustering technique to the part-machine incidence matrix to identify logical part families and machine groups. Part A B C D E Weekly quantity 50 20 75 10 12 Machine routing 327 61 65 651 3274 Part F G H I J Weekly quantity 60 5 100 40 15 Machine routing 51 3 2 4 3 2 4 7 247 561
Solution: (a) See step 1. (b) See steps 1 through 4. Step 1 A B C D E F G H I J Rank 1 1 1 1 1 5 2 1 1 1 1 1 1 3 1 1 1 1 2 4 1 1 1 1 7
2 3 7 6
Step 2 A B C D E F 1 1 1 1 1 1 1 1 1
G H I 1 1 1 1 1 1 1
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1 1
2 3 7 6 1 5 4
E 1 1 1
H 1 1 1
A 1 1 1
G 1 1
Step 3 I D 1 1 1 1 1
1 1 1
1 1
1 1 1 1
Rank 1 2 3 5 6 7 4
2 3 7 4 6 1 5 Rank
E 1 1 1 1
H 1 1 1 1
A 1 1 1
G 1 1 1
Solution: (a) Hollier method 1 0 50 0 50 2 10 0 50 60 3 Step 1: 3 0 0 0 0 4 40 0 20 60 1 From 50 0 70 50 170 4 2 Op. 1 2 3 4 From 50 0 70 50 Step 2 To 50 60 0 60 From/To ratio 1.0 0 0.83 Sequence 2 4 1 3
1 2 3 4 To
Sequence:
70 3
50
40
50
(c) % in-sequence moves = (50 + 40 + 50)/170 = 0.824 = 82.4% % bypassing moves = (20 + 10)/170 = 0.176 = 17.6% % backtracking moves = 0
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Cellular Mfg-3e-S 7-19, 21/06, 06/05/07 (d) Layout plan: In-line sequence of U-shaped layout is appropriate for the given flows with no back tracking. 18.10 In Problem 18.8, two logical machine groups are identified by rank order clustering. For each machine group, (a) determine the most logical sequence of machines for this data. (b) Construct the network diagram for the data. (c) Compute the percentages of in-sequence moves, bypassing moves, and backtracking moves in the solution. Solution: (a) Hollier method applied to first machine group (machines 2, 3, 4, 7): Step 1 Step 2 2 3 7 4 From From To From/To sums sums ratio 2 62 145 207 2 207 167 1.24 3 167 3 167 0 7 167 12 12 7 12 202 0.06 4 140 140 4 140 140 0.89 To 167 0 202 157 Sequence: 3 2 4 7
Order 2 1 4 3
167
167
145
140 12
40
17
(c) % in-sequence moves = (167 + 145 + 140)/526 = 0.859 = 85.9% % bypassing moves = 62/526 = 0.118 = 11.8% % backtracking moves = 12/526 = 0.023 = 2.3% (a) Hollier method applied to second machine group (machines 1, 5, 6): Step 1 Step 2 6 1 5 From From To From/To sums sums ratio 6 35 85 120 6 120 15 8.0 1 0 0 1 0 105 0 5 15 70 85 5 85 85 1.0 To 15 105 85 Sequence: 6 5 1
Order 1 3 2
105
85 15
70
105
75
75
(c) % in-sequence moves = (85 + 70)/205 = 0.756 = 75.6% % bypassing moves = 35/205 = 0.171 = 17.1% % backtracking moves = 15/205 = 0.073 = 7.3% 152
Cellular Mfg-3e-S 7-19, 21/06, 06/05/07 18.11 Five machines will constitute a GT cell. The from-to data for the machines are shown in the table below. (a) Determine the most logical sequence of machines for this data, and construct the network diagram, showing where and how many parts enter and exit the system. (b) Compute the percentages of in-sequence moves, bypassing moves, and backtracking moves in the solution. (c) Develop a feasible layout plan for the cell based on the solution. From: 1 2 3 4 5 1 0 0 0 70 0 2 10 0 0 0 75 To: 3 80 0 0 20 0 4 0 85 0 0 20 5 0 0 0 0 0
Solution: (a) Hollier method: Step 1 1 0 0 70 0 70 2 10 0 0 75 85 5 3 80 0 20 0 100 1 4 0 85 0 20 105 5 0 0 0 0 0 2 From 90 85 0 90 95 From sums 90 85 0 90 95 To sums 70 85 100 105 0 Step 2 From/To ratio 1.29 1.0 0 0.86
1 2 3 4 5 To
1 2 3 4 5
Order 2 3 5 4 1
Sequence:
(b) % in-sequence moves = (10 + 85 + 20)/360 = 0.319 = 31.9% % bypassing moves = (75 + 20 + 80)/360 = 0.486 = 48.6% % backtracking moves = 70/360 = 0.194 = 19.4% (d) Student exercise. There is no single correct solution for this design problem. 18.12 A GT machine cell contains three machines. Machine 1 feeds machine 2 which is the key machine in the cell. Machine 2 feeds machine 3. The cell is set up to produce a family of five parts (A, B, C, D, and E). The operation times for each part at each machine are given in the table below. The products are to be produced in the ratios 4:3:2:2:1, respectively. (a) If 35 hours per week are worked, determine how many of each product will be made by the cell. (b) What is the utilization of each machine in the cell? Part A B C D E Machine 1 4.0 min. 15.0 min. 26.0 min. 15.0 min. 8.0 min. Operation time Machine 2 15.0 min. 18.0 min. 20.0 min. 20.0 min. 16.0 min. Machine 3 10.0 min. 7.0 min. 15.0 min. 10.0 min. 10.0 min.
Solution: (a) Compute time to produce units in given ratio: Machine 1: T = 4(4) + 3(15) + 2(26) + 2(15) + 1(8) = 151 min. Machine 2: T = 4(15) + 3(18) + 2(20) + 2(20) + 1(16) = 210 min. Machine 3: T = 4(10) + 3(7) + 2(15) + 2(10) + 1(10) = 121 min. Machine 2 is the bottleneck machine that determines cell output Time available = 35(60) = 2100 min. 2100 Number of cycles to produce the products in the ratio given = = 10 cycles 210 Thus, output = 10(4 + 3 + 2 + 2 + 1) = 10(12) = 120 pc. 153
10(151) = 0.719 = 71.9% 2100 Machine 2 utilization U = 100% 10(121) Machine 3 utilization U = = 0.576 = 57.6% 2100
18.13 A GT cell will machine the components for a family of parts. The parts come in several different sizes and the cell will be designed to quickly change over from one size to the next. This will be accomplished using fast-change fixtures and downloading the part programs from the plant computer to the CNC machines in the cell. The parts are rotational type, and so the cell must be able to perform turning, boring, facing, drilling, and cylindrical grinding operations. Accordingly, there will be several machine tools in the cell, of types and numbers to be specified by the designer. To transfer parts between machines in the cell, the designer may elect to use a belt or similar conveyor system. Any conveyor equipment of this type will be 0.4 m. wide. The arrangement of the various pieces of equipment in the cell is the principal problem to be considered. The raw workparts will be delivered into the machine cell on a belt conveyor. The finished parts must be deposited onto a conveyor that delivers them to the assembly department. The input and output conveyors are 0.4 m wide, and the designer must specify where they enter and exit the cell. The parts are currently machined by conventional methods in a process-type layout. In the current production method, there are seven machines involved but two of the machines are duplicates. "From-to" data have been collected for the jobs that are relevant to this problem. From: 1 2 3 4 5 6 7 Parts in 1 0 12 74 0 0 0 174 25 2 112 0 0 82 73 0 16 0 3 0 0 0 0 0 0 20 300 To: 4 61 0 35 0 0 0 30 0 5 59 0 31 0 0 0 20 0 6 53 226 0 23 23 0 0 0 7 0 0 180 5 0 0 0 75 Parts out 0 45 0 16 14 325 0
The from-to data indicate the number of workparts moved between machines during a typical 40 hour week. The data refer to the parts considered in the case. The two categories "parts in" and parts out" indicate parts entering and exiting the seven machine group. A total of 400 parts on average are processed through the seven machines each week. However, as indicated by the data, not all 400 parts are processed by every machine. Machines 4 and 5 are identical and assignment of parts to these machines is arbitrary. Average production rate capacity on each of the machines for the particular distribution of this parts family is given in the table below. Also given are the floor space dimensions of each machine in meters. Assume that all loading and unloading operations take place in the center of the machine. Machine 1 2 3 4 5 6 7 Operation Turn outside diameter Bore inside diameter Face ends Grind outside diameter Grind outside diameter Inspect Drill Production rate 9 pc/hr 15 pc/hr 10 pc/hr 12 pc/hr 12 pc/hr 5 pc/hr 9 pc/hr Machine dimensions 3.5 m x 1.5 m 3.0 m x 1.6 m 2.5 m x 1.5 m 3.0 m x 1.5 m 3.0 m x 1.5 m Bench 1.5 m x 1.5 m 1.5 m x 2.5 m
Operation 6 is currently a manual inspection operation. It is anticipated that this manual station will be replaced by a coordinate measuring machine (CMM). This automated inspection machine will triple throughput rate to 15 parts per hour from 5 parts per hour for the manual method. The floor space dimensions of the CMM are 2.0 m x 1.6 m. All other machines currently listed are to be candidates for inclusion in the new machine cell. (a) Analyze the problem and determine the most appropriate sequence of machines in the cell using the data contained in the From-To chart. (b) Construct the network diagram for the cell, showing where and how many parts enter and exit
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Cellular Mfg-3e-S 7-19, 21/06, 06/05/07 the cell. (c) Determine the utilization and production capacity of the machines in the cell as you have designed it. (d) Prepare a layout (top view) drawing of the GT cell, showing the machines, the robot(s), and any other pieces of equipment in the cell. (e) Write a one-page (or less) description of the cell, explaining the basis of your design and why the cell is arranged as it is. Solution: (a) Use Hollier method to analyze sequence. 1 0 12 74 0 0 0 174 260 2 112 0 0 82 73 0 16 283 3 3 0 0 0 0 0 0 20 20 7 4 61 0 35 0 0 0 30 126 5 59 0 31 0 0 0 20 110 1 6 53 226 0 23 23 0 0 325 7 0 0 180 5 0 0 0 185 4,5 From 285 238 320 110 96 0 260 From sums 285 238 320 110 96 0 260 To sums 260 283 20 126 110 325 185 From/To ratio 1.096 0.841 16.0 0.873 0.873 0 1.405 Order 3 6 1 4,5 4,5 7 2
1 2 3 4 5 6 7 To
1 2 3 4 5 6 7
Sequence:
(b) Network diagram: Combine operations 4 and 5 into one operation; call it operation 4.
66 74 16 112 53 46 325 6 45 12 30 25
50 174 5 120
300 3
180 20
155
226
75
(c) Utilization and production capacity Op. 1 2 3 4* 6 7 Throughput 285 pc/wk 283 pc/wk 320 pc/wk 236 pc/wk 325 pc/wk 260 pc/wk Production rate 9 pc/hr 15 pc/hr 10 pc/hr 12 pc/hr 15 pc/hr 9 pc/hr Capacity 369 pc/wk 600 pc/wk 400 pc/wk 480 pc/wk 600 pc/wk 360 pc/wk Hrs/wk 31.7 hr 18.9 hr 32.0 hr 19.7 hr 21.7 hr 28.9 hr Utilization 0.792 0.472 0.800 0.492 0.542 0.722
* Operations 4 and 5 combined into operation 4. (d) and (e) Cell design and one page essay: Student exercises. There is no single correct solution to this design problem.
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