IET 4475 Senior Project Learning Module Two
Order ID 53563633773 Type Essay Writer Level Masters Style APA Sources/References 4 Perfect Number of Pages to Order 5-10 Pages Description/Paper Instructions
IET 4475 – Senior Project Learning Module Two
Introduction
You will prepare a process chart and a flow chart.
You will conduct simulated time studies on the different manufacturing operations.
You will create a detailed facility layout.
Instructions for Module Assignment Two
The Production ProcessAs you continue to research the details for the manufacture of your two products you may discover new information that can have a significant impact on a decision that you made previously. If you wish you may modify any decision you made previously based on the new information that you have discovered. If you decide to do this then you must revise all the previous documents that you have already submitted to match the changes that you wish to make (include your changes only in the final document). In other words, you may continue to improve the quality of your project proposal all semester if you wish to do so.
You will design a production line capable of producing the volume of product indicated by your demand forecasts.
Therefore you will create each of the following:
– A description of the final process including number of machines and direct labor requirements.
– A simulated Time Study of each manufacturing operation (you can get ideas from YouTube or visit an actual woodworking shop).– An Operation Process Chart.
– A Flow Process Chart.
– A Work Area Layout for each manufacturing operation (each type). These drawings should show the machine, the person, and all the materials required at that operation. These drawings should be separate from the Facility Layout.
– A Facility Layout for years 1, 2, 3, 4, 5 (to scale). Include vsd files (“save as”=jpg) inside the Word doc.Simulated Time Studies: You will need to conduct simulated Time Studies on each of your proposed manufacturing operations. You will need a minimum of ten time values for all the tasks that are done to each individual product, such as gluing or screwing two pieces together. You will only need one time value for tasks that process a lot of parts at one time, such as position and open a box of 100 parts. The Total Standard Time at the bottom of each Time Study should be the time for one unit of production (final finished product).
Number of Separate Time Studies: You will need one Time Study on each task in the manufacturing process. If 24 tasks are required to make the product then you will need 24 Time Studies. Each Time Study should show the total standard time to do one individual task. If one person does ten different major tasks then you will need ten separate Time Studies, one for each of the ten major tasks. If one machine is used to do four different operations, then you will need four Time Studies, or one per operation.
The reason for this amount of detail is that it will allow you, or anyone who reviews your work, to be able to calculate the exact number of machines and the exact number or people required for different sales volumes. If the sales of the new product significantly increase beyond the company’s original expectations, then the company can easily determine how many machines and people will be needed to meet the new sales requirements
(This paragraph ONLY applies to unassembled – omit if told to build complete) Unassembled Final Project: The product will be sold unassembled in a cardboard box and several boxes can be stacked onto one pallet. This will lower the shipping expense per unit and make it possible for the retailer to still earn a profit on the new product. In addition, draw a detailed sketch showing how the parts will be stacked inside a box along with any cardboard spacers required. Consider the purchase of a polybag sealing machine to seal the hardware kits. Include in your process plan how to efficiently stack the unassembled product into the shipping box.
Batch Sizes: If a machine will be used to do more than one specific type of operation then you will need to include enough time to recalibrate the machine, and to change tooling (such as drill bits), and to set stops for the next operation. These times will need to be included in the total standard time based on how many parts will be produced before the machine is switched to make a different item (the batch size). You will need to provide adequate space in the work area for each machine to store enough incoming parts, and enough space to store outgoing parts based on the batch size.
Personal, Fatigue, and Delay: Scotsman Company has extensive experience manufacturing lumber furniture and they have done extensive time studies in the past to determine that a 20% Personal, Fatigue, and Delay factor is appropriate for all of their manufacturing operations and you should therefore use 20% P, F, and D for your work standards.
Cross-Trained Employees: If one person will be operating the same machine all day then the 20% P, F, and D allows enough time to turn the machine on at the beginning of the work day and to turn the machine off at the end of the work day. However, if you decide that one person will be trained to operate more than one machine, and that person will walk between the machines during the work day, then you must include an estimate of the time required to walk between machines in your simulated Time Study, and the time to turn the machine on, and the time to turn the machine off.
For safety reasons the machines cannot be left running when unattended. Each machine is activated by a four digit code that is entered into a keypad on each machine, and it takes 20 seconds for the machine to initialize after receiving the correct four digit code. It takes 10 seconds for a machine to stop running after it is turned off. These times do not include walking between the machines or entering the four digit code. (Note: The average person can walk 3 feet per second between machines inside a typical production area. A person who is not carrying anything or pushing anything can walk 4.4 feet per second in a straight line down a straight aisle on a level floor.)
Machine Requirements Table: You will need to complete one of these tables for each product for each year (or a total of ten tables). This table is similar to Exhibit Two in the Facilities Design course. However, it has been modified for the Senior Project course and the last two columns have been omitted.
Productivity: You should use an average productivity at the top of each page for years 1 to 5. The productivity for a new process is usually between 90% to 95% because it takes time for the employees to be productive at their new jobs and it takes time and experience to learn when preventive maintenance should be done on new equipment to minimize equipment downtime during working hours. The productivity will gradually increase each year because the employees will gradually become more efficient at what they do, equipment downtime will be reduced as experience is gained with maintaining the equipment, and there will be a reduction in scheduling problems and material shortages inside the facility. Enter the following annual productivity percent in the block on the top left of the page and at the top of Columns 4 and 5.
Year One Two Three Four Five Productivity 90% 92% 94% 95% 96% Column 1 (Maximum Output per Machine Hour): Column number 1 (Maximum Output per Machine per Hour) is equal to 60 minutes divided by the number of standard allowed minutes per product (Total Standard Time) from the bottom of each Time Study Record for each manufacturing operation or assembly operation. (The standard allowed minutes or Total Standard Time needs to include the 20% P, F, and D factor.) Show the number in Column 1 to one decimal place.
Column 2 (Scrap Percent): You will need to estimate the scrap loss at each manufacturing operation. The scrap loss for each step in the manufacturing process can be between 0.0 percent to 5.0 percent. Do not use the same scrap loss for every operation. In other words, do not use 0.1% or 5.0% for every operation. Think about each job and estimate what you think a reasonable scrap loss would be for that job. For example, a cutting operation should have a much higher scrap loss than a sanding operation. Normally the lowest possible scrap loss is 0.1 percent except that a packing or palletizing operation can have a scrap loss of 0.0 percent.
Column 3 (Required Output per Hour at 100% Productivity): The last value on the bottom of Column 3 for the last operation (normally packing or palletizing) should equal the annual production output for the product divided by the number of working hours per year. In years 2 through 5 use 1,920 hours per year (240 days x 8 hours per day). However, for year 1 only use 1,520 working hours per year because it will take approximately 10 weeks to purchase and install equipment, hire and train people, and get the first products completed and shipped to your customers. As an example for year 2, if the annual output is 2,500 units for year 2 then the number at the bottom of Column 3 for the last job should be 1.30 (or 2,500 divided by 1,920 rounded to two decimal places).
You then work from the bottom of Column 3 to the top of Column 3 based on the sequence of work activities. If you have twelve major work activities and the last activity is palletizing then the value of 1.30 would be in Column 3 for the Palletizing Job. If the job just before Palletizing is Inspection and you have a 1.0% scrap loss at Inspection then the number in Column 3 for Inspection would be 1.31 (or 1.30 divided by 0.99, where 0.99 is equal to 1.00 minus the scrap rate for inspection expressed as a decimal instead of a percent.) Continue to work up Column 3 using the scrap loss at each previous job that is listed on the page.
Column 4 (Required Output per Hour at __% Productivity): Divide the number in Column 3 by the productivity and enter that value in Column 4 on the same line for the same job. For example, 1.31 divided by 0.95 equals 1.38 (rounded to two decimals) and that number would appear in Column 4 for the Palletizing Job (as an example).
Column 5 (Minimum Number of Machines at __% Productivity): Divide the number in Column 4 by the number in Column 1 for each job. For example, if the Palletizing Job has a potential Maximum Output Per Machine Hour of 30.0 units, then the number in Column 5 would be 0.05 (or 1.38 divided by 30.0 and rounded to two decimals).Inventory: Store two weeks of raw material inventory inside your raw material warehouse. Store two weeks of finished goods inside your finished goods warehouse. The existing building has 12 feet of clearance from the floor to the ceiling. This is 12 feet of open space that can be used for inventory storage in racks.
Five Year Plan: Your analysis should demonstrate that your process is capable of producing the volume demanded in each of the five years (number of machines) as well as the estimated utilization for each machine and the labor required for each of the five years. The best method is to begin with year five and then deduct from those totals for years 4, 3, 2, and 1.
Capacity: You will also need to estimate the overall percent of total plant capacity (15,000 square feet up to 20,000 square feet) that you will be utilizing each year (with year five being 100% of the space you need).
The main building already exists (as roughly illustrated in Module 1). However, the area you will be occupying is an open warehouse on one side of the building with a finished floor, ceiling, three interior walls, and one exterior wall.
There is one door in each of the three interior walls. Each door is 36 inches wide for employee traffic. The three doors may be drawn anywhere you wish in the three interior walls, with one door in each wall. You may add more employee doors if necessary. One of the interior doors leads to the main office area for Scotsman Company (i.e. HR, Purchasing, Sales, etc.) and another interior door leads to the employee services area where there are rest rooms, a locker room, a break room, and a first aid room. You do not need to include these areas in your layout because they already exist inside the main building.
There are currently no loading dock door(s) in the exterior wall in your area. You will need to add one or more loading dock doors as appropriate based on your layout. Assume an expense of $5,000 per dock door installed.
Progress Report to Management: A second report (in the same format as the first report) will be required for Module Assignment Two. You will need to include the following in your report:
– A one-page (or less) Executive Summary.
– A written description of the production process and the steps of manufacturing each product.
– Simulated Time Studies of each manufacturing operation.
– Identify all work centers and the resources and costs of each to the extent you now know them.
– An Operation Process Chart for each product (show operations and inspection points).
– A Flow Process Chart for each product of the major steps outlined in Module 1
– A Plant Layout for years 1-5.
– Each of the charts and layouts identified above. Include all drawings in the Word document.
– Include Narratives for all your charts, graphs, tables, and drawings to help explain to the reader.
Remember that the professionalism, appearance, and neatness of your report is important because a lot of the information in your report can be used in your final project document and therefore it will directly impact your grade on your final written project report.
Each student also needs to download the Student Evaluation Form from the Learning Module One folder and confidentially evaluate all the people on your team, including yourself. This form needs to be attached to an email sent to the instructor. Do not submit this form in the D2L Assignment folder.
RUBRIC
QUALITY OF RESPONSE NO RESPONSE POOR / UNSATISFACTORY SATISFACTORY GOOD EXCELLENT Content (worth a maximum of 50% of the total points) Zero points: Student failed to submit the final paper. 20 points out of 50: The essay illustrates poor understanding of the relevant material by failing to address or incorrectly addressing the relevant content; failing to identify or inaccurately explaining/defining key concepts/ideas; ignoring or incorrectly explaining key points/claims and the reasoning behind them; and/or incorrectly or inappropriately using terminology; and elements of the response are lacking. 30 points out of 50: The essay illustrates a rudimentary understanding of the relevant material by mentioning but not full explaining the relevant content; identifying some of the key concepts/ideas though failing to fully or accurately explain many of them; using terminology, though sometimes inaccurately or inappropriately; and/or incorporating some key claims/points but failing to explain the reasoning behind them or doing so inaccurately. Elements of the required response may also be lacking. 40 points out of 50: The essay illustrates solid understanding of the relevant material by correctly addressing most of the relevant content; identifying and explaining most of the key concepts/ideas; using correct terminology; explaining the reasoning behind most of the key points/claims; and/or where necessary or useful, substantiating some points with accurate examples. The answer is complete. 50 points: The essay illustrates exemplary understanding of the relevant material by thoroughly and correctly addressing the relevant content; identifying and explaining all of the key concepts/ideas; using correct terminology explaining the reasoning behind key points/claims and substantiating, as necessary/useful, points with several accurate and illuminating examples. No aspects of the required answer are missing. Use of Sources (worth a maximum of 20% of the total points). Zero points: Student failed to include citations and/or references. Or the student failed to submit a final paper. 5 out 20 points: Sources are seldom cited to support statements and/or format of citations are not recognizable as APA 6th Edition format. There are major errors in the formation of the references and citations. And/or there is a major reliance on highly questionable. The Student fails to provide an adequate synthesis of research collected for the paper. 10 out 20 points: References to scholarly sources are occasionally given; many statements seem unsubstantiated. Frequent errors in APA 6th Edition format, leaving the reader confused about the source of the information. There are significant errors of the formation in the references and citations. And/or there is a significant use of highly questionable sources. 15 out 20 points: Credible Scholarly sources are used effectively support claims and are, for the most part, clear and fairly represented. APA 6th Edition is used with only a few minor errors. There are minor errors in reference and/or citations. And/or there is some use of questionable sources. 20 points: Credible scholarly sources are used to give compelling evidence to support claims and are clearly and fairly represented. APA 6th Edition format is used accurately and consistently. The student uses above the maximum required references in the development of the assignment. Grammar (worth maximum of 20% of total points) Zero points: Student failed to submit the final paper. 5 points out of 20: The paper does not communicate ideas/points clearly due to inappropriate use of terminology and vague language; thoughts and sentences are disjointed or incomprehensible; organization lacking; and/or numerous grammatical, spelling/punctuation errors 10 points out 20: The paper is often unclear and difficult to follow due to some inappropriate terminology and/or vague language; ideas may be fragmented, wandering and/or repetitive; poor organization; and/or some grammatical, spelling, punctuation errors 15 points out of 20: The paper is mostly clear as a result of appropriate use of terminology and minimal vagueness; no tangents and no repetition; fairly good organization; almost perfect grammar, spelling, punctuation, and word usage. 20 points: The paper is clear, concise, and a pleasure to read as a result of appropriate and precise use of terminology; total coherence of thoughts and presentation and logical organization; and the essay is error free. Structure of the Paper (worth 10% of total points) Zero points: Student failed to submit the final paper. 3 points out of 10: Student needs to develop better formatting skills. The paper omits significant structural elements required for and APA 6th edition paper. Formatting of the paper has major flaws. The paper does not conform to APA 6th edition requirements whatsoever. 5 points out of 10: Appearance of final paper demonstrates the student’s limited ability to format the paper. There are significant errors in formatting and/or the total omission of major components of an APA 6th edition paper. They can include the omission of the cover page, abstract, and page numbers. Additionally the page has major formatting issues with spacing or paragraph formation. Font size might not conform to size requirements. The student also significantly writes too large or too short of and paper 7 points out of 10: Research paper presents an above-average use of formatting skills. The paper has slight errors within the paper. This can include small errors or omissions with the cover page, abstract, page number, and headers. There could be also slight formatting issues with the document spacing or the font Additionally the paper might slightly exceed or undershoot the specific number of required written pages for the assignment. 10 points: Student provides a high-caliber, formatted paper. This includes an APA 6th edition cover page, abstract, page number, headers and is double spaced in 12’ Times Roman Font. Additionally, the paper conforms to the specific number of required written pages and neither goes over or under the specified length of the paper. GET THIS PROJECT NOW BY CLICKING ON THIS LINK TO PLACE THE ORDER
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