Faculty of MECHANICAL ENGINEERING

MANAGEMENT AND MANUFACTURING ENGINEERING

final report:

FLEXIBLE MANUFACTURING

AUTHORS: LECTURER:

Julia Njoga, 232138 dr inż. Marek Stembalski

Sylwia Pawlaczyk, 199813

PROJECT:
Magdalena Żuk, 205222
Day: Mondays
Time: 11:15
Week: odd
LIST OF CONTENTS

I. Goal/objectives of the project

II. The descriptive part

a. Selection criteria of the technological operations

b. Main criteria of choice of the machine and operation

c. Selected types of machine tools

d. The machine tools quantity - i0 calculation

e. Calculation of set-up time

f. Operation sheet (route sheet)

g. Description of the quality control

h. Layout of the manufacturing system (drawing and description)

III. Simulation model of manufacturing system performed in ProModel

a. Description of the numerical model

b. Simulation results

c. Analysis of the results

IV. Conclusions

V. Attached documents and files

 I. GOAL/OBJECTIVES OF THE PROJECT

In our project we have to implement this production plan:

o we want to produce 2 different parts:

- front cover
- bottom cover: changed
o we want to produce it parallel
o we want to produce 100.000 units of one part, so total: 200.000 products
o we have to do it during one year

We have to assume, that we:

o work in 3-shifts system

o work 5 days in week
o we have less than 365 days (without weekends and holidays), so we
have to produce it within something about 250 days
Creating a model for our production plan, we should consider criteria of our
choices of machines, operations etc.

In this project, we have to realize these all objectives above, make a

decision about the main criteria, choose operations and machines, do needed
calculations. Next step will be creating a layout for our production plan, then
creating a simulation using all data in ProModel. The last part of our project will
be analysis of result from ProModel simulation and formulate a summary.
II. THE DESCRIPTIVE PART

a. SELECTION CRITERIA OF THE TECHNOLOGICAL OPERATIONS

In our model the main criteria was the cost of operation – not cost of the
machines. We decided to choose new, numerical machines – more expensive,
but faster and more precisely than conventional machines. Because of our
choice, the time of operation was shorter and production quality – better.

b. MAIN CRITERIA OF CHOICE OF THE MACHINE AND OPERATION

FRONT COVER (PP):

REQUIREMENT
OPERATION NAME
(MACHINE-TOOL TYPE, EQUIPMENT)

Rough and medium milling of machining Required CNC milling machine with
1 datum surface
Choice 2
main drive 8,5 kW electric power

Typical lathe with spindle rotation

2 Face turning, main hole processing Choice 1
speed 1800 rpm min,

3 Holes processing Choice 1

Typical milling machine with spindle
rotation velocity of 1600rpm min,
4 1 hole Ø1,5 drilling Choice 1

BOTTOM COVER – CHANGED (PTZ):

REQUIREMENT
OPERATION NAME
(MACHINE-TOOL TYPE, EQUIPMENT)

Rough and medium milling of machining Required CNC milling machine with
1 Choice 2
datum surface main drive 8,5 kW electric power

Typical machine tool with spindle

2 Face turning, main hole processing Choice 1
rotation velocity of 1800rpm

3 Holes processing Choice 1

Typical machine tool with spindle
4 1 hole Ø1,5 drilling Choice 1
rotation velocity of 1600rpm
5 Holes processing Choice 1
Looking at requirement above, we decided to choose machines, which will be
suitable for all operations:

● Turning: Lathe CNC ST-10,0

max rotational speed [rpm]: 6 000 ( > 1 800)
● Milling: Milling machine CNC VF-1.0
max rotational speed [rpm]: 7 500 ( > 1 800)
main drive electric power [kW]: 14,9 ( > 8,5)
● Drilling: Conventional drilling- milling machine BFM 200 Bernardo
max rotational speed [rpm]: 2 000 ( > 1 800)

c. SELECTED TYPES OF MACHINE TOOLS

Due to the previous point, we decided to select these machines:

Nu
Name of m Probe Robo Chip Max Max
t
palle
remo rotati Spind Spindle Tool Price Price
the be system t
avail val onal le orientati warehou
machine r of able
chan
facilit speed Powe on se
Ax ger
tool ? y [rpm] r [kW]
es Tool Object
measur. measur. euro PLN
sensor system

Milling
Wheel -
machine CNC 3 No No No No No 7500 14,9 Vertical 10slots
36995 155379
VF-1.0
Conventional
drilling-
milling 3 No No No No No 2000 7.5 Vertical N/A - 85400
machine BFM
200 Bernardo

Auto
Name of Robo matic Chip Spindle
Tool Object t mode remo max Bar
Tool Price Price
the Ax max rotatio Powe handling
measur. measur. avail val warehou
machine es sensor system
bar nal
able length facilit speed
r [kW] accessor
se
ies
tool ? Lw y [rpm]
[mm] euro PLN
 revolving
Lathe CNC X,
No No No 712 No 6000 11,2 No head - 12 33995 142779
ST-10,0 Z positions

d. THE MACHINE TOOLS QUANTITY - I0 CALCULATION

Important data below:

Number of pieces (n):

FRONT COVER: 100000

BOTTOM COVER – changed: 100000

factor of day utilisation (𝜳): 0,8

number of days (D): 250 number of shift (l): 3

Calculation:

TIMES (h) I0
QUANTIT PRICE TOTAL
MACHINE bottom bottom
Y
front cover – front cover – [PLN] PRICE
cover change cover change
d d

Lathe CNC
ST-10,0
0,016 0,012 0,33 0,25 2 142 779 285 558

Milling machine CNC VF-

1.0
0,090 0,131 1,88 2,73 5 155 379 776 895

Conventional drilling-
milling machine 0,023 0,013 0,48 0,28 2 85 400 170 800
BFM 200 Bernardo
QC (PP i PTZ) 0,032 0,026 0,25 0,21 2 1 000 2 000

TOTAL SUM OF MACHINES: 1 235 253 PLN

e. CALCULATION OF SET-UP TIME

In our project, we created layout in way, that we have separated

production line – individual for part PP and for part PTZ. Because of that, we will
have set-up time for:
MILLING-
MILLING
Actions: LATHE
MACHINE
DRILLING
MACHINE
Organizational actions connected with start and
10 min = 0,17 h 10 min = 0,17 h 12 min = 0,2 h
end work on machines

Equipment actions (mounting in the holder) 8 min = 0,13 h 10 min = 0,17 h 15 min = 0,25 h

Going to the distribution of work or

4 min = 0,07 h 4 min = 0,07 h 6 min = 0,1 h
documentation

SUM: 0,37 h 0,41 h 0,65 h

f. OPERATION SHEET (ROUTE SHEET)

FRONT COVER:

OPERATION SHEET 1. Section 2. 3. Document numer

1
4. Part symbol 5. Drawing numer 6. Part name 7.

FC (PP) PZWK 1.05 Front cover

8. 9. 10. 11. Weight [kg] 12. 13. 14. 15. 16. Operation sheet number 17.

2,40 1/1
18. Material name 19. 20.

EN-GLJ-250
21. Type of primary product 22. 23. 24. 25.

Cast iron
26. Op. number 27. 28. Machine symbol 29. 30. 31. 32. 33. 34. 35. Setup time 36. Cycle time [s] 37. 38. 39.

10 FNC 64
40. Operation name 41. 42. 43.

Rough and medium milling of machining datum surface

44. Production aid 45. 46.

20 TNC 57,6

Face turning, main hole processing

30 FNC 261,7

Holes processing

40 FV 83,7
 1 hole Ø1,5 drilling

50 QC 115

Quality control

47. Created by: 48. Checked by: 49. Approved by: 50. Date

eng. Magdalena Żuk eng. eng. 19.12.2016

BOTTOM COVER – CHANGED:

OPERATION SHEET 1. Section 2. 3. Document number

2
4. Part symbol 5. Drawing numer 6. Part name 7.

BCv2 (PTZ) PZW-02.007 Bottom Cover changed

8. 9. 10. 11. Weight 12. 13. 14. 15. 16. Operation sheet number 17.

2.00 kg 1/1
18. Material name 19. 20.

EN-GLJ-250
21. Type of primary product 22. 23. 24. 25.

Cast iron
26. Op. number 27. 28. Machine symbol 29. 30. 31. 32. 33. 34. 35. Setup time 36. Cycle time 37. 38. 39.

10 FNC 64
40. Operation name 41. 42. 43.

Rough and medium milling of machining datum surface

44. Production aid 45. 46.

20 TNC 43,6

Face turning, main hole processing

30 FNC 305,7

Holes processing

40 FV 48

1 hole Ø1,5 drilling

50 FNC 102,3

Holes processing

60 QC 95

Quality control

47. Created by: 48. Checked by: 49. Approved by: 50. Date

eng. Magdalena Żuk 19.12.2016

 g. DESCRIPTION OF THE QUALITY CONTROL

The quality control has implemented manually for both parts.

Our assumptions:

- 20% of producing parts is controlled

- 5% for all machine-tools is rejected
- tQC = 90 + n*5 [s]

CALCULATIONS FOR BOTTOM COVER: CALCULATIONS FOR BOTTOM COVER CHANGED:

Number of dimensions in IT8 quality class or better: Number of dimensions in IT8 quality class or better:

n=5 n=1

tQC = 90 + 5*5 = 115 [s] = 0,032 [h] tQC = 90 + 1*5 = 95 [s] = 0,026 [h]

h. LAYOUT OF THE MANUFACTURING SYSTEM (DRAWING AND DESCRIPTION)

We attached drawings of layout on A3 format, with all needed information and

dimensions. The most important information below:

● TABLE WITH WORKSTATIONS DIMENSIONS:

NAME OF THE DIMENSIONS

QUANTITY
MACHINE TOOL X [mm] Y [mm] Z [mm]

Milling machine CNC

3270 3400 3170 5
MiniMill 1,0

Conventional drilling-milling machine

2160 2000 2500 2
BFM 200 Bernardo

Lathe CNC ST-10,0 3000 1600 1800 2

QC (for PP & PTZ) 2000 1300 1200 2

Pallet 1200 1000 150 22

● CALCULATION OF THE AREA OF WAREHOUSES

- Hall: 25 m x 45 m = 1 125.00 m2
- R.M. Storage: 15.3 m x 7.65 m = 101.75 m2
- F.P. Storage:13.3 m x 7.65 m = 101.75 m2

● ANOTHER DIMENSIONS:

- Distance between machines: 1000 mm

- Distance to walls: 2000 mm
- Distance to paths: 3000 mm
- Width of transportation paths: 3000 mm
III. SIMULATION MODEL OF MANUFACTURING SYSTEM
PERFORMED IN PROMODEL

a. DESCRIPTION OF THE NUMERICAL MODEL

SCREEN FROM PROMODEL SIMULATION:

WAY OF GROUPING: Material is grouped in groups of 10 in every output pallet.

It assures movement of materials only in groups of 10. Groups are ungrouped in
every input pallet so the operations are performed individually.

SIZE OF BATCHES: TIME OF SIMULATION:

100 Qty Each 6069 h 37 min 59 s

FREQUENCY OF ARRIVALS: Each material appears in the model with frequency

of 6hr Occurrences for front cover is 1011 and for bottom cover changed is
1000.
There was no Failed Arrivals in our process. So there was no Arrival Lost.

We assume that 20% of components has to go through Quality Control, and 5%

of them will be a waste.

We have achieved production plan of 100 000 pieaces of each part:

INPUT:

FRONT COVER : OUTPUT:

100 080+ 1010=101 090 FRONT COVER : 100 080

BOTTOM COVER CHANGED: 108 BOTTOM COVER CHANGED:108 900

900+ 1010=109 910

b. SIMULATION RESULTS

USE OF MACHINES:

Machines that are used the most are milling machines. Use of these machines
determines total time of simulation. Basing on i0 calculation and technological
card produced parts demands most operation exactly on milling machines so
others like lathe 1,2 or Drill 1,2 are working less than 50% of the production time.
Considering fact that in the project front cover and bottom cover changed
are produced on two separate lines, i0 had to be calculated for 100.000 parts
of front cover and 100.000 parts of bottom cover changed. Due to fact that
setup times are eliminated, some of the machines was bought separately for
two produced parts yet use of the machines during simulation time could allow
to realize production plan only on one of them for two parts (eg. Lathe 1 & 2).

USE OF RESOURCES:
COST FROM PROMODEL:
 c. ANALYSIS OF THE RESULTS

Based on USE OF MACHINES maybe in future our production plan should

consider combination of the two production lines. Then it would be 1 lathe, 1
drill and 1 quality control for both parts and we would save some cost of
second machine and operator.

Based on USE RESOURCES results it can be concluded that employees

transport are not optimally used and we should reduce their number. Similarly
with machine operators drill, lathe operators and quality control staff should,
there should be less workers and they should have more duties, for example it
should be 1 operator for both lathe machines.

Analyzing the statistical cost of resources and machines, definitely should

reduce the number of employees on the lathe, drill and quality control
because looking at their use and the use of machinery they are unnecessary
expense.
COST:

Way of calculation we can see in excel file, here only results:

● SIMULATION TIME: 364 178 min = 6 070 h

● MACHINES COST: 1 235 253 PLN
● HALL COST: 1600 PLN/m2 * 25 x 45m = 1 800 000 PLN
● BLANKS COSTS: 1 706 000 PLN

● EMPLOYEE’S SALARIES:
o Transport workers: 4 x 17 PLN / h = 68 PLN / h
o Operation Workers: 9 x 20 PLN /h = 180 PLN / h
o QC workers: 2 x 15 PLN / h = 30 PLN / h

TOTAL COST OF SALARIES: 278 PLN / h

● OPERATING MACHINES COSTS:

o Milling: 4 x 150 PLN / h = 600 PLN / h
o Lathe: 2 x 150 PLN / h = 300 PLN / h
o Drill: 2 x 200 PLN / h =400 PLN / h
o QC: 2 x 80 PLN / h = 160 PLN / h
TOTAL COST OF OPERATING MACHINES: 1460 PLN / h

OPERATING PER
SIM. MACHINES HALL BLANKS EMPLOYEE’S OPERATING INVESTMENT TOTAL
MACHINES HOUR
TIME COSTS COSTS COSTS SALARIES COSTS COSTS SUM
COSTS COST

15290
6 070 1 235 253 1 800 000 1 706 000 1687460 8862200 10549660 3 035 253 1738
913

9=
1 2 3 4 5 6 7=5+6 8=2+3 7/1
4+7+8

● OPERATING COSTS: 10549660 PLN

● INVESTMENT COSTS: 3 035 253 PLN
● TOTAL SUM: 15290913 PLN
 ● PER HOUR COST: 1738 PLN

IV. CONCLUSIONS

Within a year (about 253 days), we produce 100 080 parts of FRONT
COVER and 108 900 parts of BOTTOM COVER CHANGED. To perfectly fit in the
production plan, which assumed 250 days, we could add 3 working Saturdays
during the year, for for people want to use opportunity of 150% reward for their
work day. Another solution could be to use better the equipment, especially
milling machines with better performance and a shorter working time, because
the whole process is based on them, and also they generate the most time.

While, summarizing the costs would reduce the number of employees

and give them more responsibilities, especially operators drill, lathe and
employees quality control. Moreover, definitely we would significantly reduce
transport workers and to consider the introduction of gantry crane.

Taking into account the use of machines and workers, could be

conclude, that a more optimal solution could be a combination of production
lines. This would reduce the number of machines, number of employees, thus
reduce costs, and the use of machines and workers would be more optimal.
However, it that kind of production it is necessary to take into account the time
setups, as well as the introduction of separate buffers for each type of part.

In summary, the production plan 100 000 parts of both components has
been completed, all the assumptions of the project have been met. But
certainly we should optimize our process. Introduce more solutions in the field
of lean management and based on the analysis of statistics make changes
and introduce continuous improvement plan.
V. ATTACHED DOCUMENTS AND FILES

1. Model of manufacturing system (PROMODEL file)

2. Reports from the PROMODEL in text form

3. Excel file with calculation

4. A3 Layout (pdf)