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    Automated Flow Lines

    Uploaded by

    anshu saini
    automated flow line part 2

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    © All Rights Reserved
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    Automated Flow Lines

    Uploaded by

    anshu saini
    18 views17 pages
    automated flow line part 2

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    automated flow line part 2

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    18 views17 pages

    Automated Flow Lines

    Uploaded by

    anshu saini
    automated flow line part 2

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 17

    AUTOMATED FLOW LINES

    PROBLEM
    An 8-station dial rotary indexing assembly machine, driven by a Geneva
    mechanism, has an indexing time of 3 sec and a dwell time of 5 sec.
    Under ideal conditions, the machine produces a complete assembly in 8 sec,
    achieving a production rate of 450 units/hour.
    Suppose, each station malfunctions once in every 100 cycles. One or more
    station malfunction will immediately jam the indexing machine requiring an
    operator to make adjustment to restart the machine. Suppose, the adjustment
    and restart time is 10 minutes.
    Calculate Percentage downtime, Production rate and Production efficiency.
    SOLUTION
    Chance of station malfunction = 1 in 100 cycles
    Chance that a given station will not malfunction = 99% = 0.99
    But all 8 stations must operate without malfunction to produce a completed
    assembly successfully.
    So, the probability of no malfunction in a given cycle = Product of chances
    of no malfunction at each station during that cycle
    = 0.998 = 0.9227
    Therefore, out of 10,000 machine cycles, 9227 assemblies will be produced
    without malfunction, with a cycle time of 8 sec/assembly.
    This will consume 9227× 8 = 73816 𝑠𝑠𝑠𝑠𝑠𝑠 = 20.5 ℎ𝑟𝑟𝑟𝑟.
    CONTD…
    In rest of the 773 (10,000-9227) cycles, at least 1 station will malfunction,
    requiring 10 min to repair.
    This will consume 773 × 10 min/breakdown = 7730 min = 128.83 hrs.
    Therefore, the total time to produce 9227 assemblies = 20.5 + 128.53 =
    149.33 hrs.
    128.53
     % downtime = = 0.863 = 86.3% of the total production time.
    149.33
    Now, with breakdown, production rate has been reduced from the total of
    450 units/hr to
    9227 𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢
    = 61.8 𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢/ℎ𝑟𝑟
    149.33 ℎ𝑟𝑟𝑟𝑟
    CONTD…
    𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟
     Production Efficiency =
    𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟
    61.8 𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢/ℎ𝑟𝑟
    = = 0.137 = 13.7%
    450 𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢/ℎ𝑟𝑟

    Analysis : There is a drop of 86.3% in efficiency in the breakdown condition.


    CONTD…
    Now, suppose the improvements on the automated flow line have been done so as to
    achieve the reduction in station malfunction rate from 1 in 100 cycles to say, 1 out of
    10,000 cycles.
    Let us refigure the % downtime, production rate and efficiency.
    Probability of no malfunction in a given typical cycle = 0.9998 = 0.9970
    That is in 10,000 cycles 9970 assemblies will be produced without malfunction, with a
    cycle time of 8 sec/assembly.
    This will consume 9970× 8 = 79,760 𝑠𝑠𝑠𝑠𝑠𝑠 = 22.16 ℎ𝑟𝑟𝑟𝑟.
    CONTD….
    In rest of the 30 (10,000-9970) cycles, at least 1 station will malfunction, requiring 10 min to
    repair.
    This will consume 30 × 10 min/breakdown = 300 min = 5 hrs.
    Therefore, the total time to produce 9970 assemblies = 22.16 + 5 = 27.16 hrs.
    5 ℎ𝑟𝑟𝑟𝑟
     % downtime = = 0.184 = 18.4% (from 86.3%) of the total production time.
    27.16 ℎ𝑟𝑟𝑟𝑟
    9970 𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢
     Poduction rate = = 367 𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢𝑢/ℎ𝑟𝑟
    27.16 ℎ𝑟𝑟𝑟𝑟
    𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 367
    Production Efficiency = = = 0.816 = 81.6%
    𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼𝐼 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 450
    A 30 station transfer line is being proposed to machine a certain

    PROBLEM component currently produced by conventional methods. The


    proposal received from the machine tool builder states that the line
    will operate at a production rate of 100 pc/hr at 100%
    efficiency. From a similar transfer line it is estimated that
    breakdowns of all types will occur at a frequency of F = 0.20
    breakdowns per cycle and that the average downtime per line
    stop will be 8.0 minutes. The starting blank that is machined on the
    line costs Rs. 5.00 per part. The line operates at a cost of ₹100
    per hour and the average cost per tool = Rs. 20 per cutting edge.
    Compute the following:
    1. Production rate
    2. Line Efficiency
    3. Cost per unit piece produced on the line
    SOLUTION
    𝑃𝑃𝑐𝑐 = 100 𝑝𝑝𝑝𝑝/ℎ𝑟𝑟 at 100% efficiency (ideal condition)
    F = 0.2 per cycle
    𝑇𝑇𝑑𝑑 = 8 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚
    𝑇𝑇𝑚𝑚𝑚𝑚 = ₹5/part
    𝐶𝐶𝑚𝑚 = Rs. 5/part

    Ideal cycle time per piece,


    1 1
    𝑇𝑇𝑐𝑐 = = = 0.01 hr/piece = 0.6 min/piece
    𝑃𝑃𝑐𝑐 100
    Average production time per piece,
    𝑇𝑇𝑝𝑝 = 𝑇𝑇𝑐𝑐 + (F. 𝑇𝑇𝑑𝑑 )
    𝑇𝑇𝑝𝑝 =0.6+(0.2×8)=2.2 min/piece
    CONTD….
    Average production rate,
    1 1
    𝑅𝑅𝑝𝑝 = = = 0.45 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝/𝑚𝑚𝑚𝑚𝑚𝑚=(0.45×60) piece/hr
    𝑇𝑇𝑝𝑝 2.2
    𝑅𝑅𝑝𝑝 =27 piece/hr

    Line Efficiency,
    𝑇𝑇𝑐𝑐 0.6
    E = = = 27.27%
    𝑇𝑇𝑝𝑝 2.2
    CONTD….
    Tooling cost per piece,
    (30 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡)(𝑅𝑅𝑅𝑅. 20/𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡
    𝐶𝐶𝑡𝑡 =
    100 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝
    = Rs. 6/piece

    𝐶𝐶𝑚𝑚 = Rs. 5/part

    𝐶𝐶𝑙𝑙 = 100/60 = ₹1.66/piece

    𝐶𝐶𝑝𝑝𝑝𝑝 = 𝐶𝐶𝑚𝑚 + 𝐶𝐶𝑙𝑙 . 𝑇𝑇𝑝𝑝 + 𝐶𝐶𝑡𝑡


    = 5 + (1.66×2.2) + 6
    = Rs. 14.65/piece
    TRANSFER SYSTEM IN AUTOMATED ASSEMBLY
    IN-LINE CONTINUOUS TRANSFER MACHINE
     Work carriers move at constant
    speed while the workheads index
    back and forth.
     Can not be used for heavy
    workheads and associated
    equipments due to difficulty in
    acceleration and deceleration. Moving workhead

     Ex: Food processing or


    cosmetics
    INTERMITTENT TRANSFER (SYNCHRONOUS)
    IN-LINE INDEXING
    Stationary workhead
    Intermittent transfer is the system more commonly
    employed for automatic assembly.
     Work carriers are transferred intermittently, and
    the workheads remain stationary.
    With in-line machines, provision must be made for
    returning the empty work carriers to the beginning
    of the line.

    Fig: In-line indexing machine (with one workhead shown)


    INTERMITTENT TRANSFER (SYNCHRONOUS) Stationary workhead

    IN-LINE INDEXING

    Fig: In-line transfer machine with shunting work carriers


    returned in horizontal plane
    INTERMITTENT TRANSFER (SYNCHRONOUS)
    IN-LINE INDEXING Stationary workhead

    Fig: In-line transfer machine with shunting work carriers


    returned in vertical plane.
    INTERMITTENT TRANSFER (SYNCHRONOUS)
    ROTARY INDEXING
     Assembly of the product is completed
    during one revolution of the table. Stationary workhead

    Rotary indexing machine (with one workhead shown)


    Thank you

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