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?

  • Minimized inventory
  • Maximized production
  • Improved product quality
  • Optimized profit (correct)

    • 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.

    <p>Job shop</p> Signup and view all the answers

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

    <p>Low variety</p> Signup and view all the answers

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

    <p>False</p> Signup and view all the answers

    What is the primary application of flow shops?

    <p>Mass production</p> Signup and view all the answers

    Cellular manufacturing systems are also known as ______________.

    <p>TPS</p> Signup and view all the answers

    Match the following manufacturing system types with their characteristics:

    <p>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</p> Signup and view all the answers

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

    <p>True</p> Signup and view all the answers

    What is a characteristic of a transfer line?

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

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

    <p>False</p> Signup and view all the answers

    What is the main advantage of flexible manufacturing systems?

    <p>Adaptability when faced with production changes</p> Signup and view all the answers

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

    <p>λ</p> Signup and view all the answers

    Match the following manufacturing systems with their characteristics:

    <p>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</p> Signup and view all the answers

    What is the main goal of production line balancing?

    <p>To balance the production rate of each workstation</p> Signup and view all the answers

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

    <p>False</p> Signup and view all the answers

    What is the main advantage of using a transfer line?

    <p>Very high production rates</p> Signup and view all the answers

    The Willow Run factory produced ___________ airplanes in 468 hours.

    <p>453</p> Signup and view all the answers

    What is the main consideration in factory layout planning?

    <p>Reducing transportation distance and time</p> Signup and view all the answers

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

    <p>Industry-related</p> Signup and view all the answers

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

    <p>True</p> 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)

    <p>Efficiency, productivity, or minimizing waste</p> Signup and view all the answers

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

    <p>everything</p> Signup and view all the answers

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

    <p>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</p> Signup and view all the answers

    What is the focus of production line balancing?

    <p>Optimizing machine utilization</p> Signup and view all the answers

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

    <p>True</p> 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)

    <p>Reduced material handling, improved productivity, or increased flexibility</p> Signup and view all the answers

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

    <p>physical layout</p> Signup and view all the answers

    What is the primary goal of manufacturing system design?

    <p>Increasing productivity</p> Signup and view all the answers

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

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

    Autonomous robots can be used in food processing.

    <p>True</p> Signup and view all the answers

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

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

    A ____________________ machine line is a type of production system.

    <p>deterministic</p> Signup and view all the answers

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

    <p>M/M/1 Queue</p> Signup and view all the answers

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

    <p>False</p> Signup and view all the answers

    What is the symbol for operation time in production systems?

    <p>tau</p> Signup and view all the answers

    Match the following types of production systems with their descriptions:

    <p>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</p> Signup and view all the answers

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

    <p>manufacturing</p> 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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    Description

    This quiz covers the concepts of flow shop layout and transfer lines in mechanical engineering, including their characteristics, advantages, and applications.

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