MECH60566 MANUFACTURING MANAGEMENT MECH60465 MANUFACTURING OPERATIONS (SUG1) ASSIGNMENT 2 - 2016-17 TITLE: CELLULAR MANUFACTRING HAND-IN DATE: End of module Assignment Brief Read the attached scenario and address the following instructions: a) Analyse the problem and determine the most appropriate arrangement of the machines in the cell using the data contained in the from-to chart. b) Prepare a layout (top view) sketch of the cell showing the machines, the robot(s) and any other pieces of equipment in the cell. Describe the cell, discuss the basis of your design and justify all your decisions. c) Discuss the techniques you have employed and critically appraise the importance of cellular manufacturing, comparing it with other forms of organisational structure of layouts used in manufacturing. Discuss the management implications of cellular manufacturing. d) Detail clearly any assumptions you make in addressing the above. THIS ASSIGNMENT IS WORTH 50% OF THE TOTAL MARKS FOR THIS MODULE General Assessment Criteria Marks will be awarded on the basis of the knowledge of the technique used displayed by the candidate and on the quality of analysis and discussion in applying related perspectives to the problem scenario Specific Assessment Criteria  Demonstrating knowledge and understanding of the technique. (25%).  Ability to apply the technique in context, with suitable analysis and interpretation. (25% )  Insight, deeper understanding and critical appraisal of how this and similar techniques impact on the application and management of cellular design and. Analysis (30%).  Report quality including referencing and bibliography (if appropriate), writing style, use of grammar and correct spelling (20%)Cellular Manufacturing This problem is concerned with the design of a GT cell to machine the components from a certain family of parts. The parts come in several sizes and the cell is to be designed to change over quickly from one size to the next. This will be accomplished using fast-change fixtures and direct numerical control (DNC) to download the NC program from the plant computer to the CNC machines in the cell. The parts are rotational-type components, so the cell must be able to perform turning, boring, facing, drilling and cylindrical grinding operations. Accordingly, there will be several machine tools inthe cell, of types and numbers to be specified by the designer. To transfer parts between machines in the cell, one or more large robots will be used. The robot to be used has jointed arm configuration with a reach of 2.0m. Its base measures 1.0m x 1.0m. The designer may also elect to us' a belt or similar conveyor system to move parts within the cell. Any conveyor equipment of this type will be 0.4m wide, The arrangement of the various pieces of equipment in the cell is the principal problem to be considered. The raw workparts will be delivered into the machine cell or a belt conveyor to a fixed location so that the robot can pick up each part to start it through the cell. The raw parts are forgings so that the parts are ready for machining. The finished parts must be deposited onto a conveyor that delivers them to the assembly department. The input and output conveyors are 0.4m wide, and the designer must specify how they enter and exit the cell. The five parts are currently machined by conventional methods in a process-type layout. In the current production method, there are seven machines involved but two of the machines are virtual duplicates. From-to data have been collected for the jobs that are relevant to this problem. To: From 1 2 3 4 5 6 7 Parts Out 1 0 112 0 61 59 53 0 0 2 12 0 0 0 0 226 0 45 3 74 0 0 35 31 0 180 0 4 0 82 0 0 0 23 5 16 5 0 73 0 0 0 23 0 14 6 0 0 0 0 0 0 0 325 7 174 16 20 30 20 0 0 0 Parts In 25 0 300 0 0 0 75The from-to data indicate the number of workparts moved between machines during a typical 40-hour week. The data refer to the five parts considered in the case. The two categories "parts in" and "parts out" indicate parts entering and exiting the seven-machine group. A total of 400 parts on average are processed through me seven machines per week. However, as indicated by the data, not all 400 parts are processed by every machine. Machines 4 and 5 are identical and assignment of parts to these machines is arbitrary. Average production rate capacity on each of the machines for the particular distribution of this part family is given in the table below. Also given are the floor space dimensions of each machine in metres. Assume that all loading and unloading operations take place on the centre of the machine. Machine Operation Production Rate (pc/h) Machine Dimensions (m) 1 Turn OD 9 3.5 x 1.5 2 Bore ID 15 3.0 x 1.6 3 Face ends 10 2.5 x 1.5 4 Grind OD 12 3.0 x 1.5 5 Grind OD 12 3.0 x1.5 6 Inspect 5 Manually done 7 Drill 9 1.5 x 2.5 Operation 6 is currently a manual inspection operation. It is anticipated that this manual section will be replaced by a coordinate measuring machine (CMM). This automated inspection machine will triple the throughput rate from 5 parts per hour for the manual method to 15 parts per hour. The floor space dimensions of the CMM are 2.0 x 1.6m. All of the other machines currently listed are to be candidates for inclusion in the new machine cell. (a) Analyse the problem and determine the most appropriate arrangement of the machines in the cell using the data contained in the from-to chart. (b) Prepare a layout (top view) sketch of the GT cell, showing the machines, the robot(s), and any other pieces of equipment in the cell. Write a description of the cell, explaining the basis of your design and why the cell is arranged as it is. (c) Discuss the techniques used.