Assignment 3 Manufacturing Models and Metrics
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University of Southern Mississippi *
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Course
406
Subject
Industrial Engineering
Date
Apr 3, 2024
Type
docx
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Scott, Melanie
IET 406: Industrial Automation
Assignment 3
Manufacturing Models and M
etric
s
(13
points)
Descriptive Questions (7 p
o
in
ts
)
Descriptive questions
1.
What is the cycle time in a manufacturing operation? (1 point)
The time spent for the conversion of raw materials into finished products. The cycle time is the time that one work unit spends being processed or assembled. It is the time interval between when one work unit begins processing (or assembly) and
when the next unit begins. It is the time an individual part spends at the machine, but not all of this is processing time.
2.
What is manufacturing lead time? (1.5 points)
It is the time period between the placement of an order and the shipment of the order to a customer. Time between process initiated and completed.
The cycle time is the time that one work unit spends being processed or assembled. It is the time interval between when one work unit begins processing (or assembly) and when the next unit begins. It is the time an individual part spends at the machine, but not all of this is processing time.
3.
What is work-in-process? (1.5 points)
It is the amount of goods that are partially finished/processed and are waiting to get completed to make the sale possible.
plant’s work-in-process (WIP) is the quantity of parts or products currently located in the factory that either are being processed or are between processing operations. WIP is inventory that is in
the state of being transformed from raw material to finished part or product.
4.
How are fixed costs distinguished from variable costs in manufacturing? (1.5 points) Fixed costs are expenses that remain the same no matter how much a company produces, such as rent, property taxes, insurance, and depreciation. Variable costs are any expenses that change based on how much a company produces and sells, such as labor, utility expenses, commissions, and raw materials. 5.
Name five typical factory overhead expenses? (1.5 points)
Factory rent
Depreciation
Property Taxes
Insurance
Indirect materials
Mathematical Analysis (6 points)
6.
An average of 20 new orders are started through a certain factory each month.
On average, an order consists of 50 parts that are processed sequentially through
10 machine-operations in the factory. The operation time per machine for each
part = 15 min. The non-operation time per order at each machine averages 8
hours, and the required setup time per order = 4 hours. There are a total of 25
Scott, Melanie
machines in the factory working in parallel. Each of the machines can be set up
for any type of job processed in the plant. Only 80% of the machines are
operational at any time (the other 20% are in repair or maintenance). The plant
operates 160 hours per month. However, the plant manager complains that a
total of 100 overtime machine hours must be authorized each month in order to
keep up with the production schedule. Determine the following:
(a) What is the manufacturing lead time for an average order?
MLT= n(Ts+QTc+Tno)
MLT=10[4hr+(50 partsX15minx1hr/60min)+8hr]
MLT= 245 hrs/order
(b) What is the plant capacity (on a monthly basis) and why must the overtime be authorized? Tp = (4 + 50x0.25)/50 = 16.5/50 = 0.33 hr/pc, Rp = 3.0303 pc/hr
PC = (25x0.80)(160)(3.0303)/10 = 969.7 pc/month
Parts launched per month = 20x25 = 1000 pc/month
Schedule exceeds plant capacity by 1000 - 969.7 = 30.3 pc.
This requires overtime in the amount = (30.303 pc x 10 machines)/(3.0303 pc/hr)=
100
hr.
This is why overtime must be authorized to meet the production demand.
(c) What is the utilization of the plant according to the definition given in the text? (1.5 points)
Utilization U = (1000 pc)/(969.7 pc) = 1.03125 = 103.125%
(d) Determine the average level of work in process (number of parts in process) in the plant. WIP = (245 hr)(969.7 pc/mo)(1.03125)/(160 hr/mo) = 1531.25 parts
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