PS7 V1 F23
pdf
keyboard_arrow_up
School
Cornell University *
*We aren’t endorsed by this school
Course
MISC
Subject
Industrial Engineering
Date
Jan 9, 2024
Type
Pages
2
Uploaded by hooooope
CHEME 5610: Product Design/Lean Operations Design
Problem Set #7 (40 Points): Assigned October 26, 2023
Due: November 9, 2023
Page
1
of
2
Fall 2023: AW
Homework Problems:
1.
A large pharma. company has recently gotten feedback that one of their vaccines will have an
increase in demand for syringe based product instead of vial based product.
In anticipation of
this increase in demand you as the lead process engineer for the area have been assigned to
analyze the process and define recommendations for improvements that will ensure the line
can meet demand and also potentially reduce costs. Demand for the syringe product is expected
to be at 52 million syringes per year.
The production facility is run 24/7 all year long except
for a 3 week shutdown in the winter and a 2 week shutdown in the summer each year to do site
maintenance.
The operators on the floor work 2X12 hr. shifts with 1 hr. for lunch and 3X20
minute breaks per shift.
The process starts with boxes of clean empty glass syringes shrink wrapped (sealed) having
to undergo a sterilization process via E-Beam irradiation prior to filling.
The boxes are
delivered to the sterilizer from the warehouse by the warehouse people and the operators take
the boxes in loads of 10 and load them into the sterilizer chamber. Each box contains 1000
syringes.
The sterilizer cycle is run for its validated run time of 30 minutes.
The boxes are
then removed from the chamber and the next group/batch loaded.
The load and unload time
is all called “set-up/change-over”.
The set-up/change-over data that your team collected
ranges from 30 minutes to 90 minutes for each load. There are 3 employees that work in this
operation.
The sealed sterilized boxes are then placed in a small vault for storage until
needed in the next step.
There are typically 50 boxes in this vault area.
The sterilized syringes are then feed into an automated syringe filling station that runs at the
machine rated capacity of 160 ppm (pieces per minute).
The unit has demonstrated 20%
downtime with the downtime associated with glass breakage clean-up, machine jams, and
stopper jams.
Glass breakage accounts for 10% defects that are discarded in this step.
Two
people work on the line to help minimize downtime along with supply the parts to the
machine to keep it running.
Directly adjacent to the filling station connected by a conveyor belt is the inspection station
where each syringe is inspected by optical devices looking for over/under fills, extraneous
matter, cracked syringes).
The inspection machine has a rated capacity of 140 ppm and runs
with an excellent uptime performance of 97%.
However, the inspection process results in
approx. 15 syringes per minute being rejected.
Causes for the rejection are attributed to
cracked syringes, under fills (below target volume specifications), and crooked stoppers on
the syringes.
The syringes are packed off the line in flat boxes that contain 500 syringes per
box.
Two people work the inspection systems to ensure maximum uptime by minimizing
downtime issues.
Currently in the warehouse there are 10,000 boxes of filled/inspected
syringe inventory waiting for packaging.
Final packaging for the customer is performed in the adjacent building.
The boxes of filled
syringes are loaded in the packaging unit.
The packaging unit then takes the individual
CHEME 5610: Product Design/Lean Operations Design
Problem Set #7 (40 Points): Assigned October 26, 2023
Due: November 9, 2023
Page
2
of
2
Fall 2023: AW
syringes and packs them into final customer boxes of 5 syringes each.
The packaging unit
can process syringes through to final pack at a rate of 140 syringes per min.
The uptime for
the packaging line is running at 85% due to cartoner jams.
Four people work on the
packaging unit feeding the syringes and moving completed customer boxes to the shipping
dock along with addressing equipment jamming.
1)
(10 pts)
What is the takt time (minutes/syringe) and thus the resulting minimum rate
(pieces per minutes a.k.a. syringes per minute) the line must run in order to meet demand?
Show all calculations
2)
(15 pts)
Draw the current condition of the process from glass syringe feed through to final
pack to the customer.
Clearly show all relevant data such as design run rates (capacity) in
syringes per minute for each, uptime, actual run rates, defect streams/rate, FTEs, etc.
3)
(2 pts)
Is the line balanced?
If not, why and where?
4)
(3 pts)
Can the line meet demand as it is currently running?
Explain your reasoning along
with data.
5)
(8 pts)
What kaizens do the production floor personnel need to focus on in order to
sustainably meet the demand?
6)
(2 pts)
What can be done to reduce lead-time?
2.
Extra Credit:
(10 pts)
Read Sections II and IV in “The Toyota Way”.
Summarize the key points in no more than
a single page/single spaced and come to class prepared to discuss.
Your preview ends here
Eager to read complete document? Join bartleby learn and gain access to the full version
- Access to all documents
- Unlimited textbook solutions
- 24/7 expert homework help