When the production figures for each press line are calculated, it shows the raw processing power of the part lines. What the figures don't show is the impact and coordination of specific parts production with regard to an actual work environment. Items such as lunch, breaks and equipment failures are important items that need to be accounted for. Larger part runs can also make the old system more efficient if it's permissible to carry inventory. Typically, a schedule is produced that will allow for die changes with the minimum amount of workers (don't schedule die changes on two lines for the same time since that would require two crews) and for a degree of efficiency that can be tolerated by the business model. The previous problem stated a run of enough parts to make 1000 cars with the current system running at 10 strokes/min. This small run forces die changes more frequently than larger runs would On a constant production basis, there is no end to the quantity to be produced. Develop a production schedule for the 1000 parts from the previous work on both the old and the new systems. Optimize it. then do the same for a constant production run. Here's the point: the larger the run, the more parts you can run on the old system before you need to change a die. That's fine if you can hold the inventory. Choose what you think would be a realistic number for a part lot in a constant production setting and run that through the old and the new lines. Which one will allow for the most flexibility? How would you compare the two systems? Make a production schedule for both and compare them with the schedule for making 1000 parts? Which one would be less expensive? Make up comprehensive schedules to compare the 1000 part run and the constant production run. For the comparison, both the old and new presses require the same amount of operators, but the old system almost always needs a die change crew working while the new one does not. Write up and fully describe how you would go about comparing the systems. Include how many press lines you think you would need for the new system and a qualitative analysis of any cost savings. You are a tool designer at a large automobile manufacturer. You work in the pressroom at a car plant in a small town. The plant is re-tooling for a new model. Part of the re-tooling program requires more efficiency out of the body-panel press lines. This is your job. The body-side output press lines hit 10 strokes/min. Your plant has currently has 4 part lines. Each part line consists of 2 press lines of 5 presses per line, so production can run while dies are being changed. The current feeding system is a simple pick-and-place system between presses and die changes are performed manually. A die change takes 3 hours, 4 die-setters, 1 electrician, 1 machine repairman and 2 die-makers with the current presses. The blank loading system is a simple manually loaded pallet system with a 100 blank capacity and a 15 minute change time. A sustained output of 500 cars per 8 hour shift is to be maintained during full production. There are 10 major body parts that need to be pressed: Item No Part Press speed Qty/hit Qty/car 1 Body-side (left side) 7 spm 2 Body-side (right side) 7 spm 3 Floor pan 7 spm 4 Spider 10 som Hood (outer) 12 spm 6 Hood (inner) 12 som Door (left, outer) 12 spm 8 Door (left, inner) 12 spm 9 Door (right, outer) 12 spm 10 Door (right, inner) 12 spm 5 7 NN- For the start of the project, make up a spreadsheet in Excel or a worksheet in Mathcad that calculates the amount of time necessary to make enough parts for 1,000 cars with the current system. Make sure that you figure in that a shift is 8 hours and that may break up the production. Clearly detail how the calculations are made as we will be using this sheet later. e(s) will not have two press lines, just one. They will have an Automatic Die Changer, though that can change the dies in 2 minutes, and only needs 2 die-setters and 1 die-maker. The new lines will also be able to do 12 strokes/minute for every part. Run a calculation to estimate how many lines would be needed. When the production figures for each press line are calculated, it shows the raw processing power of the part lines. What the figures don't show is the impact and coordination of specific parts production with regard to an actual work environment. Items such as lunch, breaks and equipment failures are important items that need to be accounted for. Larger part runs can also make the old system more efficient if it's permissible to carry inventory. Typically, a schedule is produced that will allow for die changes with the minimum amount of workers (don't schedule die changes on two lines for the same time since that would require two crews) and for a degree of efficiency that can be tolerated by the business model. The previous problem stated a run of enough parts to make 1000 cars with the current system running at 10 strokes/min. This small run forces die changes more frequently than larger runs would On a constant production basis, there is no end to the quantity to be produced. Develop a production schedule for the 1000 parts from the previous work on both the old and the new systems. Optimize it. then do the same for a constant production run. Here's the point: the larger the run, the more parts you can run on the old system before you need to change a die. That's fine if you can hold the inventory. Choose what you think would be a realistic number for a part lot in a constant production setting and run that through the old and the new lines. Which one will allow for the most flexibility? How would you compare the two systems? Make a production schedule for both and compare them with the schedule for making 1000 parts? Which one would be less expensive? Make up comprehensive schedules to compare the 1000 part run and the constant production run. For the comparison, both the old and new presses require the same amount of operators, but the old system almost always needs a die change crew working while the new one does not. Write up and fully describe how you would go about comparing the systems. Include how many press lines you think you would need for the new system and a qualitative analysis of any cost savings. You are a tool designer at a large automobile manufacturer. You work in the pressroom at a car plant in a small town. The plant is re-tooling for a new model. Part of the re-tooling program requires more efficiency out of the body-panel press lines. This is your job. The body-side output press lines hit 10 strokes/min. Your plant has currently has 4 part lines. Each part line consists of 2 press lines of 5 presses per line, so production can run while dies are being changed. The current feeding system is a simple pick-and-place system between presses and die changes are performed manually. A die change takes 3 hours, 4 die-setters, 1 electrician, 1 machine repairman and 2 die-makers with the current presses. The blank loading system is a simple manually loaded pallet system with a 100 blank capacity and a 15 minute change time. A sustained output of 500 cars per 8 hour shift is to be maintained during full production. There are 10 major body parts that need to be pressed: Item No Part Press speed Qty/hit Qty/car 1 Body-side (left side) 7 spm 2 Body-side (right side) 7 spm 3 Floor pan 7 spm 4 Spider 10 som Hood (outer) 12 spm 6 Hood (inner) 12 som Door (left, outer) 12 spm 8 Door (left, inner) 12 spm 9 Door (right, outer) 12 spm 10 Door (right, inner) 12 spm 5 7 NN- For the start of the project, make up a spreadsheet in Excel or a worksheet in Mathcad that calculates the amount of time necessary to make enough parts for 1,000 cars with the current system. Make sure that you figure in that a shift is 8 hours and that may break up the production. Clearly detail how the calculations are made as we will be using this sheet later. e(s) will not have two press lines, just one. They will have an Automatic Die Changer, though that can change the dies in 2 minutes, and only needs 2 die-setters and 1 die-maker. The new lines will also be able to do 12 strokes/minute for every part. Run a calculation to estimate how many lines would be needed