1585 No of Pages : 3 Course Code : 13MC11 / 13MN10 Rol N. (To be filled in by the candidate) PSG COLLEGE OF TECHNOLOGY, COIMBATORE - 641 004. SEMESTER EXAMINATIONS, MAY - 2013 ME— CIM / INDUSTRIAL ENGG,”~ Semester : 2 [PhD (PT) MECH 13MCI1/13MNI0 MODELING AND ANALYSIS OF ADVANCED MANUFACTURING SYSTEMS Time : 3 Hours ‘Maximum Marks + 100 (INSTRUCTIONS: c ee 2 << I. Answer ALL questions from PART — A and Answer any $ questions from PART -B Question under PART - C is Compulsory, PART-A Marks: 10x3=30 1..What is cycle time’in a manufacturing operation? Mlustrate with an example. 2. Deling the principle of interchangeability, How is it useful in line balancing? 3. Consider two stationing where the firsi station fails or: the average of every 20 cycles and the second'station averages ‘a failure of every 30 cycles. Both station failures are Operation dependent, Average repair lime is 4 cycles for both stations. Find the line availability. 4. List the typical objectives of implementing cellar manufacturing, 5. Use relevant algorithm to find the sequence for the three ‘machines and four jab flow ‘shop problem, Job] Processing Times {min} mcr [MiG2 [Mice Ti {3 440 2 1 1 fs (73 7 3 13 Lis 10 12 2 6. What are the five calegories of material transport equipment commonly used to'move paris and materials inside a lacilty? 7. A unit load ASIRS is baing designad to store 1000 pallét loads in a distibution center located next to the factory. Pallet dimensions are x = 1000 mm, y.=1200 mm and the maximum teight of unit load is 1300. mm. Tha AS/RS will consist of two aisles with one S/R. machine per aisle. The length of the structure should be approximately five times its height and the-rask structure will b8-built S00 mm above the floor level. Using the allowances a =150 mm, b =200 mm and ¢ =250 mm,,determine the width, length and height of the AS/RS rack structure. 8. Differentiate single command and dual command cycles with respect 10 AS/RS. Differentiate ‘Merging’ and ‘Synchronization’ 10. The parts arrive to the machining ¢entre at a rate ol 8 parts’hr. The service rate, failure rato and repair rate of the machining centre are 10, 0.2 and 0.7 per hour respectively. Determine the expected number of parts in the system and the expecied waiting time in the system. Page No: 11585 No of Pages : 3 Course Code : 13MC11 / 13MN10 PART-B Marks : 5x 10 = 50 11, The weekly quantities and routings of ten parts listed in Table are being considered for cellular manufacturing in.a machine shop. Parts are:entified by letters, and machines ‘are identified numerically. For thé data given, (a) Develop the part-machine incidence matrix (b) Apply the rank order clustering technique to identify logical part families and machine groups. Pant [Weekly | Machine Part | Weakly | Machine. Quantity | Routing Quantity | Routing A_ [50 35257 F [60 51 B 20 631 a 05 33254 c__([75 635 H__[ 100) 9323437 D [70 62551 1/40 23407 Ey [2 geae7s4| [sis 53051 12, Eight: paris are considered for an automated work call, ‘These parts are’ curently purchased from a_verdor. The new developed work cell will be available, 250 hrs per Period .The cell is charged atthe rate of Ps.500/hr, which includes all related expenses. Which parts shoukd be added to the new cell? i 2 3 l4 5 & 7 aC Unit purchasa'| 2000 | 1550 |-9000 | 1250 | 30007 | 860 | 990. “p 1650 price (As) Naierial cost (Fis) | 450 _[350__| 7240 | 500. | 1200 [340 [360 [7140 Demand = per] 1007/50 (50.475 [60 |a0-°[50 |e00} period eo fs - . Hours peruni [70 [20 (40 lio [20 [10 [70 os 13.4300 it long roller conveyor which operates at a velocity of 80 fimin, is used io move pals between load and unload stations. Each pallet carries 12 pans. Cycle time to load a pallet is 15 sec. and one worker at the load station is able to load pallets at the rato, of 4 par min. It takes 12 586 to unload at the unload station. Datermine (a) canter: ‘to center distance between pallets {b} the number of pallets on the conveyor at one time and (c) haurty flow rate of parts (d) By how much must the conveyor speed be increased te increase flow rate to 3000 parts/hour. 14.(_Censider the set of jobs shown in the following table, This is a five- job), tour- ‘machine general job shop problem. Generate.a schedule and compute make span and utilization for each machine. (5) Jeb | Operation (Machina, Processing Time Hrs) 1 2 [8 + (Aa) (G2) 6.3) D4) i z (C.1t) | (D,5) {A,3). {B,4) 3 (Day C4) a7y [1B,12) 4 (aay ice) [e.9) 10.6) 5 (D.7) (C.14) | (A.3) | 1B,8) (i) An automated guided vehicle is being planned(fer a warehouse complex. The AGV's will be a diiverless train system and each train wil consist of the towing vehicle plus four carts. Speed of the trains will be 160 {t/min, Only the pulled carts Garry loads. The average loaded travel distance per dolivary cycle is 2000 tt and empty travel distance is the same. Anticipated travel factor = 0.95. Assume reliability = 1:0. The lead handling time per wain per delivery is expected to Page No: 21585 No of Pages : 3 Course Code : 13MC11 / 13MN10 15.(i) (ii, 16.40 (i) he 10 min. Ifthe requirements on the AGV's are 25 cart loads per hour, determine the number of trains required (8) Consider a simple manutacturing system comprising two machines MIG1and M/C. 2. The job type Pt can be processed on both M/G1 and M/G 2, but-the job type P2 can be pragessed only on M/C1.On completion of processing part, the part is unloaded from the system and the fresh part of the same.type is loaded imo: the system: Model this problem using Peirinets and analyza: (8) Specify systematic layout design procedure with a help of flow diagram. (5) ‘Compare tha following CNC systems for cost effectiveness. The first system has a CNG oachine with production rate of 20 parts/hr and the. second has a CNC machine with rate 40 pansihr, The maintenance cost of the first system is Rs, 250 Per month and that of the second system is As. 365 per month. The arrival rate of ‘raw material 6 16/hr for both the systems. The inveniory cost of parts is As. 2 par. part per hr. Assume 240 working hrs per month (5) Explain the vehicle guidance technologies used for AGV's pathways (5) PART-C Marks : 1x 20-= 20 17. Two models A and_B’are to be assembled on a mixed model line. Hourly production fates tor the two.madels are: A,25 units/hr and B,1B unitsihr. The work elements, ‘element times, and precedence requirements are given in the table. Elements 6 and 8 are not required for madel A.and elements'4.and 7 are not.required tor model B. Assume E=1.0, E1 (a) ) c) {d) fe) 1.0 and Mi =1 Construct the precedence diagram:tor each madel_and fer both models’ combined inio one diagram Find the: theoretical minimum number of, work stations required to achieve the Fequired production rate Use Kilbride and Wester method te'solve tha line balancing problem. Determine tha balance efficiency for your solution: Justily yeur solution for proper line balancing [Work Element] Tay. | Preceded | Tag, [Preceded k (min) by (min) by 7 05 0S 5 2 0.3. 03 i 3 jor os [ot 4 oe os co - 5 1.2 13 23 6 * - O4 3 7 06 a5. ~ { 8 : OF 56 9 05 7 05 8 Tre 42 45 FDRL. /END/. Page No: 3