Chapter 2 Problems 2.9 2.10
Chapter 2 Problems 2.9 2.10
Body
A-1
#2
Bushing
SA-1
#3
#4
Stem
Packing
SA-2
#5
#6
A-2
Cap
Handle
A-3
#7
Assemble Cap
Assemble Handle
Nut
Final Inspection
Parts
Body
Bushing
Stem
Fiber packing
Cap
Handle
Nut
Part No.
001
002
003
004
005
006
007
Material
Cast Bronze
Cast Bronze
3/8 in. bar stock
(Purchased part)
3/4 in. hex bar stock
Cast Bronze
(Purchased part)
Assembly Operations
No
Operation
Machine
1
2
3
4
Final Assembly
Clean
Inspect (Pressure test)
Pack in boxes
Work Bench
Solvent tank
Water test stand
Work Bench
Standard
(min / part)
2.00
0.60
1.20
0.12
Operation No.
001
001-1
002-2
001-3
002
002-1
002-2
002-3
003
003-1
005
005-1
Cast
Clean
Machine Thread
and face three
surface
Cast
Clean
Machine all I.D. and
O.D.
Machine all surface
and cut off
Machine all surface
006
006-1
006-2
006-3
006-4
Cast
Clean
Machine two surface
Broach square hole
Bench mold
Tumble barrel
Turret lathe
Standard Time
(min/part)
1.50
0.40
2.40
Bench mold
Tumble barrel
Turret lathe
0.75
0.20
1.00
Automatic screw
machine
Automatic screw
machine
Bench mold
Tumble barrel
Turret lathe
Broach
0.30
0.12
1.20
0.30
0.75
0.75
Note: 100% inspection is required for all fabricated parts prior to delivery to final assembly.
(8) The machine shop estimates the following fabrication times for processing batches of 500 parts:
Body: 3 days
Bushing: 3 days
Stem: 1 day
Cap: 1 day
Handle: 2 days
Construct an operation process chart, precedence diagram, route sheets, and a Gantt chart for the production of
the gate valve. Develop a summary of equipment requirements for the production of 500 gate valves per hour.
2.10 Eight parts (A to H) are to be manufactured and assembled to produce two products (X and Y). The processing
sequence for the parts and assembled sequences for the products are given below. The daily production rate for product
X is 400 and for product Y is 600.
(a) Determine the daily production rates for each part.
(b) Design a product layout for manufacturing and assembling each product.
(c) Design a process layout for manufacturing both products.
(d) Design a group layout for manufacturing the two products.
(e) Construct a from-to chart for the daily flow of parts between processes.
(f) Construct an activity relationship chart for each product and a combined REL chart for the two products.
(g) Using the traditional SLP approach, design a REL diagram for each REL chart constructed in part (f).
The Plant Layout Problem
Part
A
B
C
D
E
F
G
H
Machine
Bench mold
Tumble mill
Milling machine
Turret lathe
Automatic screw
machine
Drill press
Punch press
Press brake
A
3.0
1.1
2.4
3.5
--
B
4.25
0.7
3.4
1.7
--
----1.3
------
----
----
----
1.5
0.3
0.8
Parts
E
------
2.2
0.5
1.2
------
----0.6
----0.9
1.1
0.4
1.1
----
----