Material Handling Student Design Competition Case Issues Tracking Document
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1 Material Handling Student Design Competition Case Issues Tracking Document Prepared for CICMHE, The College Industry Council on Material Handling Education November 8, 2011 Version 2.0 This document is for the exclusive academic usage of the Material Handling Student Design Competition.
2 Table of Contents I. PURPOSE OF THAT DOCUMENT ISSUES... 4 QUESTION/ISSUE #1: SHEET "RESOURCE TYPE - CAPABILITY"... 4 QUESTION/ISSUE #2: SHEET "RESOURCE TYPE - CAPABILITY"... 4 QUESTION/ISSUE #3: SHEET "RESOURCE TYPE - CAPABILITY"... 4 QUESTION/ISSUE #4: SHEET "RESOURCE TYPE - CAPABILITY"... 4 QUESTION/ISSUE #5: SHEET "RESOURCE TYPE - CAPABILITY"... 4 QUESTION/ISSUE #6: SHEET "RESOURCE TYPE - CAPABILITY"... 4 QUESTION/ISSUE #7: SHEET "RESOURCE TYPE - CAPABILITY"... 5 QUESTION/ISSUE #8: SHEET "RES. TYPE SPEC. RATEBYHR"... 5 QUESTION/ISSUE #9: SHEET "RES. TYPE SPEC. RATEBYHR"... 5 QUESTION/ISSUE #10: SHEET "HEADTYPE (SETUP TABLE)"... 5 QUESTION/ISSUE #11: PAGE 6 OF THE PACKET, POINT # QUESTION/ISSUE #12: SHEET "RESOURCE TYPE - CAPABILITY"... 6 QUESTION/ISSUE #13: SHEET "RES. TYPE SPEC. RATEBYHR"... 6 QUESTION/ISSUE #14: PAGE 6 OF THE PACKET, POINT # QUESTION/ISSUE #15: SHEET RESOURCE TYPE CAPABILITY... 6 QUESTION/ISSUE #16: SHEET MACHINE 119, 120,121 ARE DUPLICATED... 6 QUESTION/ISSUE #17: SHEET HEADTYPE (SETUP TABLE)... 6 QUESTION/ISSUE #18: TAW MANUFACTURING PROCESS... 7 QUESTION/ISSUE #19: SURFACE TREATMENT (ANNEALING, PHOSPHATE AND TNT, )
3 I. PURPOSE OF THAT DOCUMENT This document is used to track questions and answers and comments about issues raised by the students. 3
4 1. ISSUES Question/Issue #1: sheet "Resource Type - Capability" For Manufacturing process "Coating": Machine_119, Machine_120 and Machine_121 are duplicated. Question/Issue #2: sheet "Resource Type - Capability" For Manufacturing process "Electro - Zinc (Yellow)": Machine_119, Machine_120 and Machine_121 are duplicated. Question/Issue #3: sheet "Resource Type - Capability" For Manufacturing process "Oil Quench": Machine_61, Machine_62, Machine_63 and Machine_64 are duplicated. Question/Issue #4: sheet "Resource Type - Capability" For Manufacturing process "Quality Test": Machine_124 is duplicated. Question/Issue #5: sheet "Resource Type - Capability" For Manufacturing process "Annealing": Machine_70 is duplicated. Question/Issue #6: sheet "Resource Type - Capability" For Manufacturing process "Galvanization": Machine_119, Machine_120 and Machine_121 are duplicated. 4
5 Question/Issue #7: sheet "Resource Type - Capability" Machines 28, 65, 66, 72, 81, and are missing entirely. Answer: Yes... In that case, it is the responsibility of the design team to decide what to do with that piece of information. If a machine is not capable to process any manufacturing process... it means? Question/Issue #8: sheet "Res. Type Spec. RateByHr" There are no rates for machines 28, 65, 66, 81, and For machines 28,65,66,81, , the answer is simple (see issue #7). Machine_126 is for the process "storage". In that case, there is no processing time at all... Question/Issue #9: sheet "Res. Type Spec. RateByHr" Values are duplicated for some combinations "Resource Type - Part - Op Id". Answer: We have removed the duplicates. The new version of the excel document fixes that error. All processing times have been reviewed for the resource specific rates per hour and for the operation batch times. Question/Issue #10: sheet "HeadType (Setup Table)" "We don't understand how it could take up to 12 hrs to change a head on a machine" Answer: The setup means to change all components of the die. It forces the operator to remove the material, to uninstall the dies, to install the new dies, to calibrate the dies and adjust the mechanical tolerances. Question/Issue #11: page 6 of the packet, point #17 In the forging department (cold and hot forging), the following setup rules must be considered: a. Change of Head Type: sequence dependent setup (see table HeadType (Setup Table) in the excel document) b. Change of Grade: setup time of 30 minutes c. Change of Length Type: setup time of 45 minutes Answer: Setup Time = Max (setup a., setup b., setup c.). Setups are concurrent... 5
6 Question/Issue #12: sheet "Resource Type - Capability" Answer: For Manufacturing process Threading: Machine_82 is duplicated. The new version of the excel document fixes that error. Question/Issue #13: sheet "Res. Type Spec. RateByHr" Some combination "part - operation" should not appear in that list and should appear only in the sheet "Operation Batch Time". See issue #9. Question/Issue #14: page 6 of the packet, point #27 "Cost to build the plant can be estimated at $125 per square foot." vs Table on page 8. Are the costs on the table the basis for the average, or are they in addition to it? Do we need to address the individual costs, or should we assume that the totals are sufficient? Answer: do not consider point 27 anymore. Consider the table of point 31 Question/Issue #15: sheet Resource Type Capability " Machine 100 -> 118 are missing (there cost and size is in the resourse type tab) Answer(hint): a machine that can t achieve any process should not be used in your design process Question/Issue #16: sheet Machine 119, 120,121 are duplicated " Machine 119, 120,121 are duplicated. Answer(hint): these machines (or finishing lines) can achieve several surface treatments. Question/Issue #17: sheet HeadType (Setup Table) Question: "The first was about the head of the screws, If we receive the steel in bulk rolls, then we need to create a head on the part. It gives us a setup time to change the head from type 1 to type 10 but it does not give us an initial setup to create the head type 0 to type 1 Answer: let s assume 4 hours of setup type (head type change) for the first time you use an instance of a machine (forging machine). It is your responsibility to determine if it is relevant to 6
7 use that assumption. After that first setup, the logic of the HeadType (Setup Table) should be used. In finite scheduling, this table is used to determine the sequence of products. (Hint: For your design process, you should use that piece of information to create clusters of products) Question/Issue #18: TAW Manufacturing Process Question: "It also did not tell us what TAW is, we are assuming that TAW is an annealing process we are not sure Answer: Yes, TAW stands for (Tantalum Tungsten). In that case, the products don t go through the main surface treatment lines (Machine_119, Machine_120, Machine_121). You will find the process times in the sheet Res. Type Spec. RateByHr. Question/Issue #19: Surface Treatment (Annealing, Phosphate and TNT, ) General Comment: Machine_119, Machine_120 and Machine_121 can accomplish several surface treatments. Read carefully points #18, # 29 and #30 of the word document. 7
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