Sharjah Manufacturer Inc. is planning to establish a facility for manufacturing

Question

Sharjah Manufacturer Inc. is planning to establish a facility for manufacturing 20 parts using seven different machines. The routing information, including setup times, processing times, batch size, and annual demand for manufacturing facility is given in the following table. Estimate the minimum number of machines of each type required assuming 40 hours per week operation for 50 weeks at 90% efficiency. It is anticipated that the utilization of each machine will be 90% (due to part and material handling equipment or operator unavailability, machine down time, etc.). You may make any other necessary assumptions Construct a from-to chart Construct a relationship chart a. b. c.

Explanation / Answer

Using the table given above, we first populate the total number of batches for each part, the total set-up time for each part and the total processing time for each part.

Total Time Available = 40 hours per week * 50 weeks = 2000 Hours
Given that machines will work at 90% efficiency and total available time is 90%
Thus Actual Time Available = 2000 * 0.9 * 0.9 = 1620

To find the minimum number of machine of each type required we first need to calculate the total number of hours of work to be done on each machine. It can be calculated using the data from the above table. On adding the set-up and processing time on each machine, we get the following. Then by dividing the total time on each machine by 1620 we get the number of machines of each type that are needed.

b. Using the table given in the question we can construct the from to chart by looking at the sequence of machining. For eg. for Part 1 600 units will go from machine 01204 to machine 02008. The above information can be tabulated as follows.

c) Relationship Chart:

Using the above From - To chart we can develop the relationship chart. More the number of units in from-to chart between two machines more is the need for them to be close to each other. For the Relationship chart we shall use the following symbols to signify closeness requirement
A: Absolutely Necessary (if From -to > 2000)
E: Especially Important (if From -to > 1000)
I: Important (if From -to > 500)
O: Ordinary Closeness (if From -to > 100)
U: Unimportant (If No From -to)

Part No Demand Batch Size Machine Name Set-up time per batch Processing Time Per Batch Total Number of batches Total Set-Up Time Total Processing Time 1 600 10 01204 3 3.64 60 180 218.4 10 02008 3 5.98 60 180 358.8 2 900 10 01204 5 2 90 450 180 10 02008 2.25 1 90 202.5 90 10 02014 0.5 1 90 45 90 3 500 10 01204 4 2 50 200 100 10 02008 1 3 50 50 150 4 500 10 02008 1.5 3 50 75 150 10 02023 0.5 8.27 50 25 413.5 10 02008 0 2 50 0 100 10 02014 2 2 50 100 100 5 1220 10 02008 1 2 122 122 244 10 02014 1 6.86 122 122 836.92 10 02023 1 10 122 122 1220 6 900 10 02030 0.5 84.58 90 45 7612.2 10 02023 1 26.78 90 90 2410.2 7 700 10 02008 1 1 70 70 70 10 02023 1 1 70 70 70 8 900 10 02030 0.75 1.25 90 67.5 112.5 10 02014 0.5 1 90 45 90 10 02029 0 0.31 90 0 27.9 9 600 10 02029 8 65 60 480 3900 10 02014 0 2.23 60 0 133.8 10 250 10 02030 0.5 5 25 12.5 125 10 02008 1 7 25 25 175 11 400 10 02029 8 55 40 320 2200 10 02014 1 2.67 40 40 106.8 12 300 10 01204 2.89 8.68 30 86.7 260.4 10 02008 1 8 30 30 240 13 900 10 02029 0 8.55 90 0 769.5 10 02030 0 19.37 90 0 1743.3 10 02014 1.5 2.8 90 135 252 14 600 10 02029 0 7.53 60 0 451.8 10 02030 1 3 60 60 180 10 02014 0.75 1 60 45 60 15 450 10 02030 1 2.91 45 45 130.95 10 02030 1.5 3.83 45 67.5 172.35 16 500 10 01204 4 3.64 50 200 182 10 02008 0.75 3 50 37.5 150 17 400 10 02030 0 30.57 40 0 1222.8 10 02023 0.5 2 40 20 80 18 900 10 02029 0 12.01 90 0 1080.9 10 02030 0 7.59 90 0 683.1 10 02023 0.75 14.5 90 67.5 1305 19 900 10 02029 0 23.25 90 0 2092.5 10 02030 0 23.63 90 0 2126.7 10 02008 0 42.67 90 0 3840.3 20 250 10 02029 0 7.28 25 0 182 10 02030 0 23 25 0 575 10 02023 1 2 25 25 50

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