Three possible manufacturing systems can be used to produce a certain product, 1) ten universal milling machines that work in series, each one is producing a specific geometry, 2) one dedicated broaching machine with a roller conveyor for handling, or 3) 4 CNC milling machines working independently and a shuttle for material handling.
1. Name the three manufacturing systems.
2. What are the characteristics of each system?
3. List the types of flexibility that may exist in a manufacturing system.
3. Discuss if and how the 3 systems can adapt to a change in production volume or product design.
4. Which manufacturing system is more flexible?
5. Identify and briefly discuss the various types of possible flexibility sources in that system?
6. If the capacity of a single universal milling machine is 20 unit/hr and a defect rate of 5%, 100 unit/hr for the broaching machine and a defect rate of 2%, and 20 unit/hr for a single CNC milling machine and a defect rate of 2.5%, determine the throughput of each system.
7. Make the necessary modification in number of machines in each of the 3 systems to bring throughput up to 110 unit/hr. What are the reached utilization levels?
8. After a year of operation and with the same throughput of 110 unit/hr, there is a 60% chance for a product change, which means an extra universal milling machine will be added ($100,000), a major modification to the broaching machine will be performed ($200,000), and a change to pallet shape is required in the shuttle ($100,000). Determine which system is more desirable and justify your answer, if initial investments for system 1 is $500,000, system 2 is $800,000, and system 3 is $1000,000.