Mechanical Engineering: Flow Shop Layout and Transfer Lines

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Questions and Answers

What is the primary goal of minimizing waiting time in manufacturing?

Optimized profit

A flow shop follows a flexible structure.

False

What type of manufacturing system is characterized by a wide variety of skills and high-skilled workers?

Job shop

____________ manufacturing systems are designed to produce small batches of products or custom products.

Job shop Signup and view all the answers

Which of the following is a characteristic of a flow shop?

Low variety Signup and view all the answers

Flexible manufacturing systems (FMS) are designed for high-volume production.

False Signup and view all the answers

What is the primary application of flow shops?

Mass production Signup and view all the answers

Cellular manufacturing systems are also known as ______________.

TPS Signup and view all the answers

Match the following manufacturing system types with their characteristics:

Job shop = Wide variety of skills, high-skilled workers Flow shop = Fixed linear structure, low flexibility Flexible manufacturing systems = Low-to-medium volume, high flexibility Cellular manufacturing = Grouped by process order of product Signup and view all the answers

Idle work-in-progress inventory is a type of waste in manufacturing.

True Signup and view all the answers

What is a characteristic of a transfer line?

Operates like a single machine producing one unit per cycle Signup and view all the answers

Flexible manufacturing systems are designed to produce a single product type.

False Signup and view all the answers

What is the main advantage of flexible manufacturing systems?

Adaptability when faced with production changes Signup and view all the answers

The formula for Little's Law is L = ___________ * W

λ Signup and view all the answers

Match the following manufacturing systems with their characteristics:

Transfer Line = Synchronous production line with several machines and workstations Flexible Manufacturing System = Allows adaptability when faced with production changes Cellular Manufacturing System = Organizes machines into cells to produce a family of products Signup and view all the answers

What is the main goal of production line balancing?

To balance the production rate of each workstation Signup and view all the answers

Cellular manufacturing systems are designed to produce a single product type.

False Signup and view all the answers

What is the main advantage of using a transfer line?

Very high production rates Signup and view all the answers

The Willow Run factory produced ___________ airplanes in 468 hours.

453 Signup and view all the answers

What is the main consideration in factory layout planning?

Reducing transportation distance and time Signup and view all the answers

What is a challenge in manufacturing systems that is related to the industry?

Industry-related Signup and view all the answers

In a manufacturing system, workpieces can be starved or blocked.

True Signup and view all the answers

What is the primary concern in manufacturing system design? (Answer should be related to efficiency, productivity, or minimizing waste)

Efficiency, productivity, or minimizing waste Signup and view all the answers

According to Rule #1, nothing happens until _______________________ is present and ready.

everything Signup and view all the answers

Match the following components of a manufacturing system with their corresponding descriptions:

Machines = 2. Equipment used to perform the operation Operator = 1. Human worker involved in the operation Consumables = 3. Materials used up during the operation Post-operated part = 4. Output of the operation Waste = 5. Unwanted output of the operation Signup and view all the answers

What is the focus of production line balancing?

Optimizing machine utilization Signup and view all the answers

In a flexible manufacturing system, the same machine can perform different operations.

True Signup and view all the answers

What is the main advantage of cellular manufacturing systems? (Answer should be related to reduced material handling, improved productivity, or increased flexibility)

Reduced material handling, improved productivity, or increased flexibility Signup and view all the answers

Factory layout planning involves arranging the _______________________ of a factory to improve efficiency.

physical layout Signup and view all the answers

What is the primary goal of manufacturing system design?

Increasing productivity Signup and view all the answers

What are the two reasons why Little's Law is useful?

System is steady state or stationary, and can apply to subsystems Signup and view all the answers

Autonomous robots can be used in food processing.

True Signup and view all the answers

What is an application of Little's Law in industry?

BMW manufacturing facility in Greer, South Carolina, U.S. Signup and view all the answers

A ____________________ machine line is a type of production system.

deterministic Signup and view all the answers

What type of queue is represented by the notation M/M/1?

M/M/1 Queue Signup and view all the answers

A zero buffer line is a type of production system with infinite buffer capacity.

False Signup and view all the answers

What is the symbol for operation time in production systems?

tau Signup and view all the answers

Match the following types of production systems with their descriptions:

Deterministic Systems = Production systems with known and fixed parameters Stochastic Systems = Production systems with random and variable parameters Flexible Manufacturing Systems = Production systems that can produce multiple products Cellular Manufacturing Systems = Production systems that use cells or groups of machines Signup and view all the answers

Factory layout planning is an important step in the design of a ____________________ system.

manufacturing Signup and view all the answers

Study Notes

Flow Shop Layout

A synchronous production line with multiple machines and workstations integrated into one system, connected by conveyor systems
Operates like a single machine, producing one unit per cycle
Advantages: • Very high production rates • Reduced labor cost • Reduced work-in-process • Reduced transportation distance and time

Transfer Lines

A synchronized production line with multiple machines and workstations integrated into one system
Operates like a single machine, producing one unit per cycle
Advantages: • Very high production rates • Reduced labor cost • Reduced work-in-process • Reduced transportation distance and time

Flexible Manufacturing Systems (FMS)

Allows adaptability when faced with production changes
Consists of several machine tools, parts, and tool handling devices
Flexibility: management similar to job shop

Cellular Manufacturing Systems

Enables adaptability when faced with production changes
Consists of several machine tools, parts, and tool handling devices
Flexibility: management similar to job shop

Little's Law

Average time = average number of customers / average arrival rate
Applies in steady-state systems where the mean arrival rate is constant
Example: Willow Run Factory, producing 453 airplanes in 468 hours

Waiting

Goal: minimize waiting time to optimize profit
Waiting causes: • Under-utilization • Idle workforce • Inventory buildup

Manufacturing System Types

1. Job shop: wide variety of skills, high-skilled workers, produces small batches of products or custom products
1. Flow shop: fixed linear structure, grouped by process order, low flexibility, high volume
1. Transfer lines: synchronized production line with multiple machines, high production rates
1. Flexible Manufacturing Systems (FMS): adapts to production changes, similar to job shop
1. Cellular Manufacturing: adapts to production changes, similar to job shop

Machine Line

Unreliable machine: machine failure affects production
1 machine line: deterministic systems, can be modeled using D/D/1 queue
1 machine line: stochastic systems, can be modeled using M/M/1 queue
Multiple machines and inventory: complex systems with multiple variables

Challenges in Manufacturing Systems

Industry-related challenges: • External factors affecting production
Inherent challenges: • Machine reliability • Operator reliability • Material availability • Process variability

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Mechanical Engineering: Flow Shop Layout and Transfer Lines

Questions and Answers

What is the primary goal of minimizing waiting time in manufacturing?

A flow shop follows a flexible structure.

What type of manufacturing system is characterized by a wide variety of skills and high-skilled workers?

____________ manufacturing systems are designed to produce small batches of products or custom products.

Which of the following is a characteristic of a flow shop?

Flexible manufacturing systems (FMS) are designed for high-volume production.

What is the primary application of flow shops?

Cellular manufacturing systems are also known as ______________.

Match the following manufacturing system types with their characteristics:

Idle work-in-progress inventory is a type of waste in manufacturing.

What is a characteristic of a transfer line?

Flexible manufacturing systems are designed to produce a single product type.

What is the main advantage of flexible manufacturing systems?

The formula for Little's Law is L = ___________ * W

Match the following manufacturing systems with their characteristics:

What is the main goal of production line balancing?

Cellular manufacturing systems are designed to produce a single product type.

What is the main advantage of using a transfer line?

The Willow Run factory produced ___________ airplanes in 468 hours.

What is the main consideration in factory layout planning?

What is a challenge in manufacturing systems that is related to the industry?

In a manufacturing system, workpieces can be starved or blocked.

What is the primary concern in manufacturing system design? (Answer should be related to efficiency, productivity, or minimizing waste)

According to Rule #1, nothing happens until _______________________ is present and ready.

Match the following components of a manufacturing system with their corresponding descriptions:

What is the focus of production line balancing?

In a flexible manufacturing system, the same machine can perform different operations.

What is the main advantage of cellular manufacturing systems? (Answer should be related to reduced material handling, improved productivity, or increased flexibility)

Factory layout planning involves arranging the _______________________ of a factory to improve efficiency.

What is the primary goal of manufacturing system design?

What are the two reasons why Little's Law is useful?

Autonomous robots can be used in food processing.

What is an application of Little's Law in industry?

A ____________________ machine line is a type of production system.

What type of queue is represented by the notation M/M/1?

A zero buffer line is a type of production system with infinite buffer capacity.

What is the symbol for operation time in production systems?

Match the following types of production systems with their descriptions:

Factory layout planning is an important step in the design of a ____________________ system.

Study Notes

Flow Shop Layout

Transfer Lines

Flexible Manufacturing Systems (FMS)

Cellular Manufacturing Systems

Little's Law

Waiting

Manufacturing System Types

Machine Line

Challenges in Manufacturing Systems

Studying That Suits You

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