A certain job shop specializes in one-of-a-kind orders defiling with parts of medium to high complexity. A typical part is processed through ten machines in batch sizes of one. The shop contains eight conventional machine tools and operates35 hr/1lk ot production time Average time values on the part are: machining time per machine > 0.5 hr, work handling time per machine = 0.3 hr, tool change time per machine = 0.2 hr, setup time per machine = 6 hr, and nonoperation time per machine = 12 hr.A new programmable machine has been purchased by the shop which is capable of performing all ten operations in a single setup. The programming of the machine for this part will require 20 hr; however, the programming can be done off-line, without tying up the machine. The setup time will be 10 hr. The total machining time will be reduced to 80% of its previous value due to advanced tool control algorithms: the work handling time will be the same as for one machine: and the total tool change time will be reduced by 50% because it will be accomplished automatically under program control. Fur the one machine, nonoperation time is expected to be 12 hr.
(a) Determine the manufacturing lead time for the traditional method and for the new method.
(b) Compute the plant capacity for the following alternatives:
(i) e job shop containing the eight traditional machines, and
(ii) a job shop containing IWI) of the new programmable machines. Assume the typical jobs are represented by the data given above.
(c) Determine the average level of work-in-process for the two alternatives in part (b). if the alternative shops operate at full capacity.
(d) Idenhfy which of the ten automation strategies (Sect 1.5,2) arc represented {or probably represented] by the new machine.