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CORK INSTITUTE OF TECHNOLOGY
INSTITIÚID TEICNEOLAÍOCHTA CHORCAÍ
Autumn Examinations 2008/
Module Title: Manufacturing Systems
Module Code: MANU 8004
School: Mechanical and Process Engineering
Programme Title: Bachelor of Engineering (Honours) in Biomedical Engineering - Award Bachelor of Science (Honours) in Process Plant Technology - Award Bachelor of Science (Honours) in Advanced Manufacturing Technology - Award Bachelor of Engineering (Honours) in Mechanical Engineering - Award
Programme Code: EBIOM_8_Y3, EBIOM_8_Y4, EPPTE_8_Y4, EAMTE_8_Y4, EMECH_8_Y3, EMECH_8_Y
External Examiner(s): Mr. N. Kingston, Mr. J. Phelan
Internal Examiner(s): Mr.M O’Mahony , Ms. Bryan
Instructions: Answer THREE questions
Duration: 2 Hours
Sitting: Autumn 2009
Requirements for this examination: None
Note to Candidates: Please check the Programme Title and the Module Title to ensure that you are attempting the correct exaination. If in doubt please contact an Invigilator.
Q1. (a) Define the function of inventory in industry (5 Marks)
(b) What are the assumptions made for calculating the economic batch quantity (9 Marks) (c) The demand for a particular item is 10,000 units per annum. It costs €20 to create an order and it costs 20% of the value of the item for storage (i.e. i = 20%). If the cost of the item is as follows calculate the quantity that should be ordered?:
- C = €5/unit for 0 – 499units;
- C = €4-50/unit for 500 – 1000
- C = €3-90/unit for > 1000 units (9 Marks) (d) Table Q1 list the demand for a company’s products in the last two years on a per month basis. Projected demand for the coming year is 15,000 units. Calculate the seasonal index, and determine the expected monthly demand for the coming year. (10 Marks)
Demand Month 04 05 Jan 75 70 Feb 80 80 Mar 95 100 Apr 125 130 May 120 135 Jun 130 140 Jul 100 110 Aug 95 100 Sep 80 90 Oct 75 80 Nov 70 70 Dec 65 70 Table Q
Q4. A Model J Wagon is to be assembled on a conveyor belt. 500 wagons are required per day.
Production time per day is 420 minutes. The assembly steps and times for the wagon are given in the Table Q4.
(a) Use the Rank Positional Weight method, obtain a suitable allocation of work elements to work stations in the assembly line. (20 Marks) (b) Calculate the balance delay and balance loss (4 Marks) (c) By considering a re-distribution of work elements, show how an improvement on the solution obtained in (a) above can be realized. (9 Marks)
Table Q Step Time (seconds)
Description Steps that must precede A 45 Position rear axle support and hand fasten four screws to nuts
B 11 Insert rear axle^ A C 9 Tighten rear axle assembly and hand fasten with four screws to nuts
B
D 50 Position front axle assembly and hand fasten with four screws to nuts
E 15 Tighten front axle assembly screws^ D F 12 Position rear wheel #1 and fasten hubcap^ C G 12 Position rear wheel #2 and fasten hubcap^ C H 12 Position front wheel #1 and fasten hubcap^ E I 12 Position front wheel #2 and fasten hubcap^ E J 8 Position wagon handle shaft on front axle assembly and hand fasten bolt and nut
F,G,H,I
K 9 Tighten bolt and nut J
