ET 484 Adv Mfg

04 Problems on Flexible Manufacturing Systems

Bottleneck Model
1. A flexible manufacturing cell consists of two machining workstations plus a
load/unload station. The load/unload station is station 1. Station 2 performs
milling operations and consists of one server (one CNC milling machine).
Station 3 has one server that performs drilling (one CNC drill press). The three
stations are connected by a part handling system that has one work carrier.
The mean transport time is 2.5 min. The FMC produces three parts, A, B, and
C. The part mix fractions and process routings for the three parts are
presented in the table below. The operation frequency fijk = 1.0 for all
operations. Determine: (a) maximum production rate of the FMC, (b)
corresponding production rates of each product, (c) utilization of each machine
in the system, and (d) number of busy servers at each station.
Part j
A

Part mix
pj
0.2

0.3

0.5

Operation
k
1
2
3
4
1
2
3
4
1
2
3
4

Descripti
on
Load
Mill
Drill
Unload
Load
Mill
Drill
Unload
Load
Drill
Mill
Unload

Station i
1
2
3
1
1
2
3
1
1
3
2
1

Process time
tijk
3 min.
20 min.
12 min.
2 min.
3 min.
15 min.
30 min.
2 min.
3 min.
14 min.
22 min.
2 min.

2. Solve Problem 1 except the number of servers at station 2 (CNC milling

machines) = 3 and the number of servers at station 3 (CNC drill presses) = 2.
Note that with the increase in the number of machines from two to five, the
FMC is now a FMS according to our definitions.

3. A FMS consists of three stations plus a load/unload station. Station 1 loads and
unloads parts from the FMS using two servers (material handling workers).
Station 2 performs horizontal milling operations with two servers (two identical
CNC horizontal milling machines). Station 3 performs vertical milling
operations with three servers (three identical CNC vertical milling machines).
Station 4 performs drilling operations with two servers (two identical drill
presses). The machines are connected by a part handling system that has two
work carriers and a mean transport time = 3.5 min.. The FMS produces four
parts, A, B, C, and D, whose part mix fractions and process routings are

presented in the table below. The operation frequency fijk = 1.0 for all
operations. Determine: (a) maximum production rate of the FMS, (b) utilization
of each machine in the system, and (c) average utilization of the system, using
the server average Us.
Part j
A

Part mix
pj
0.2

0.2

0.25

0.35

Operation
k
1
2
3
4
5
1
2
3
4
5
6
1
2
3
4
1
2
3
4

Descripti
on
Load
H. Mill
V Mill
Drill
Unload
Load
Drill
H. Mill
V. Mill
Drill
Unload
Load
H. Mill
Drill
Unload
Load
V. Mill
Drill
Unload

Station i
1
2
3
4
1
1
4
2
3
4
1
1
2
4
1
1
3
4
1

Process time
tijk
4 min.
15 min.
14 min.
13 min.
3 min.
4 min
12 min.
16 min.
11 min.
17 min.
3 min.
4 min
10 min.
9 min.
3 min.
4 min.
18 min.
8 min.
3 min.

4. Solve Problem 3 except the number of carriers in the part handling system =
3.
5. Suppose it is decided to increase the utilization of the two nonbottleneck
machining stations in the FMS of Problem 4 by introducing a new part, part E,
into the part mix. If the new product will be produced at a rate of 2 units per
hour, what would be the ideal process routing (sequence and processing
times) for part E that would increase the utilization of the two non-bottleneck
machining stations to 100% each. The respective production rates of parts A,
B, C, and D will remain the same as they are in Problem 4. Disregard the
utilizations of the load/unload station and the part handling system.
6. A semi-automated flexible manufacturing cell is used to produce three
products. The products are made by two automated processing stations
followed by an assembly station. There is also a load/unload station. Material
handling between stations in the FMC is accomplished by mechanized carts
that move tote bins containing the particular components to be processed and
then assembled into a given product. The carts transfer tote bins between
stations. In this way the carts are kept busy while the tote bins are queued in
front of the workstations. Each tote bin remains with the product throughout
processing and assembly. The details of the FMC can be summarized as
follows:

Station
1
2
3
4
5

Description
Load and
unload
Process X
Process Y
Assembly
Transport

Number of servers
2 human workers
1 automated server
1 automated server
2 human workers
Number of carriers to be
determined.

The product mix fractions and station processing times for the parts are
presented in the table below. The same station sequence is followed by all
products: 1 2 3 4 1.
Produc
tj
A
B
C

Product mix
pj
0.35
0.25
0.40

Station
1
3 min.
3 min.
3 min.

Station
2
9 min.
5 min.
4 min.

Station
3
7 min.
8 min.
6 min.

Station
4
5 min.
5 min.
8 min.

Station
1
2 min.
2 min.
2 min.

The average cart transfer time between stations is 4 minutes. Use the
bottleneck model to determine: (a) What is the bottleneck station in the FMC,
assuming that the material handling system is not the bottleneck? (b) At full
capacity, what is the overall production rate of the system and the rate for each
product? (c) What is the minimum number of carts in the material handling
system required to keep up with the production workstations? (d) Compute the
overall utilization of the FMC. (e) What recommendations would you make to
improve the efficiency and/or reduce the cost of operating the FMC?
7. A flexible manufacturing system is used to produce four parts. The FMS
consists of one load/unload station and two automated processing stations
(processes X and Y). The number of servers for each station type is to be
determined. The FMS also includes an automated conveyor system with
individual carts to transport parts between servers. The carts move the parts
from one server to the next, drop them off, and proceed to the next delivery
task. Average time required per transfer is 3.5 minutes. The following table
summarizes the FMS:
Station
1
Station
2
Station
3
Station
4

Load and
unload
Process X
Process Y
Transport
system

Number of human servers (workers) to be

determined
Number of automated servers to be
determined
Number of automated servers to be
determined
Number of carts to be determined

All parts follow the same routing, which is 1 2 3 1. The product mix and
processing times at each station are presented in the table below:
Produc
tj
A

Product mix
pj
0.1

Station
1
3 min.

Station
2
15
min.

Station
3
25
min.

Station
1
2 min.

0.3

3 min.

0.4

3 min.

0.2

3 min.

40
min.
20
min.
30
min.

20
min.
10
min.
5 min.

2 min.
2 min.
2 min.

Required production is 10 parts per hour, distributed according to the product

mix indicated. Use the bottleneck model to determine: (a) the minimum number
of servers at each station and the minimum number of carts in the transport
system that are required to satisfy production demand; and (b) the utilization of
each station for the answers above.
Extended Bottleneck Model
8. Use the extended bottleneck model to solve problem 1 with the following
number of parts in the system: (a) N = 2 parts and (b) N = 4 parts. Also
determine the manufacturing lead time for the two cases of N in (a) and (b).
9. Use the extended bottleneck model to solve problem 2 with the following
number of parts in the system: (a) N = 3 parts and (b) N = 6 parts. Also
determine the manufacturing lead time for the two cases of N in (a) and (b).
10.Use the extended bottleneck model to solve problem 3 with the following
number of parts in the system: (a) N = 5 parts, (b) N = 8 parts, and (c) N = 12
parts. Also determine the manufacturing lead time for the three cases of N in
(a), (b), and (c).
11.Use the extended bottleneck model to solve Problem 4 with the following
number of parts in the system: (a) N = 5 parts, (b) N = 8 parts, and (c) N = 12
parts. Also determine the manufacturing lead time for the three cases of N in
(a), (b), and (c).
12.For the data given in Problem 6, use the extended bottleneck model to develop
the relationships for production rate Rp and manufacturing lead time MLT each
as a function of the number of parts in the system N.
13.A flexible manufacturing system is used to produce three products. The FMS
consists of a load/unload station, two automated processing stations, an
inspection station, and an automated conveyor system with an individual cart
for each product. The conveyor carts remain with the parts during their time in
the system, and therefore the mean transport time includes not only the move
time, but also the average total processing time per part. The number of
servers at each station is given in the following table:
Station 1
Station 2
Station 3
Station 4
Transport

Load and
unload
Process X
Process Y
Inspection
Conveyor

2 workers
3
4
1
8

servers
servers
server
carriers

system
All parts follow either of two routings, which are 1 2 3 4 1 or 1 2
3 1, the difference being that inspections at station 4 are performed on only
one part in four for each product (f4jk = 0.25).. The product mix and process
times for the parts are presented in the table below:
Produc
tj
A
B
C

Part mix
pj
0.2
0.3
0.5

Station
1
5 min.
5 min.
5 min.

Station
2
15 min.
10 min.
20 min.

Station
3
25 min
30 min.
10 min.

Station
4
20 min.
20 min.
20 min.

Station
1
4 min.
4 min.
4 min.

The move time between stations is 4 min. (a) Using the bottleneck model, show
that the conveyor system is the bottleneck in the present FMS configuration,
and determine the overall production rate of the system. (b) Determine how
many carts are required to eliminate the conveyor system as the bottleneck. (c)
With the number of carts determined in (b), use the extended bottleneck model
to determine the production rate for the case when N = 8; that is, only eight
parts are allowed in the system even though the conveyor system has a
sufficient number of carriers to handle more than eight. (d) How close are your
answers in (a) and (c)? Why?
14.A flexible manufacturing cell consists of a manual load/unload station, three
CNC machines, and an automated guided vehicle system (AGVS) with two
vehicles. The vehicles deliver parts to the individual machines, drop off the
parts, then go perform other work. The workstations are listed in the table
below, where the AGVS is listed as station 5.
Statio
n
1

Description

Load
unload
Milling

3
4

Drilling
Grinding

AGVS

Servers

and 1 worker
1
CNC
milling
machine
1 CNC drill press
1
CNC
grinding
machine
2 vehicles

The FMC is used to machine four workparts. The product mix, routings, and
processing times for the parts are presented in the table below:
Part
j
A

Part mix
pj
0.25

Station
1
4 min.

Station
2
8 min.

Station
3
7 min.

0.33

Station
routing
1234
1
1321

4 min.

9 min.

0.12

1241

4 min.

0.30

1243
1

4 min.

10
min.
6 min.

10
min.
0
12
min.

Station
4
18
min.
0

Station
1
2 min.

14
min.
16
min.

2 min.

2 min.

2 min.

The mean travel time of the AGVS between any two stations in the FMC is 3 min.
which includes the time required to transfer loads to and from the stations.
Given that the loading on the system is maintained at 10 parts (10 workparts in
the system at all times), use the extended bottleneck model to determine: (a)
the bottleneck station, (b) the production rate of the system and the average
time to complete a unit of production, and (c) the overall utilization of the
system, not including the AGVS.
Sizing the FMS
15.A flexible machining system is being planned that will consist of four
workstations plus a part handling system. Station 1 will be a load/unload
station. Station 2 will consist of horizontal machining centers. Station 3 will
consist of vertical machining centers. Station 4 will be an inspection station.
Four the part mix that will be processed by the FMS, the workloads at the four
stations are: WL1 = 7.5 min., WL2 = 22.0 min., WL3 = 18.0 min., and WL4 =
10.2 min. The workload of the part handling system WL5 = 8.0 min. The FMS
will be operated 16 hours per day, 250 days per year. Maintenance will be
performed during nonproduction hours, so uptime proportion (availability) is
expected to be 97%. Annual production of the system will be 50,000 parts.
Determine the number of machines (servers) of each type (station) required to
satisfy production requirements.
16.In Problem 15, determine (a) the utilizations of each station in the system for
the specified production requirements, and (b) what is the maximum possible
production rate of the system if the bottleneck station were to operate at 100%
utilization.
17.Given the part mix, process routings, and processing times for the three parts
in Problem 1. The FMS planned for this part family will operate 250 days per
year and the anticipated availability of the system is 90%. Determine how
many servers at each station will be required to achieve an annual production
rate of 40,000 parts per year if (a) the FMS operates 8 hours per day, (b) 16
hours per day, and (c) 24 hours per day. (d) Which system configuration is
preferred, and why?
18.Given the part mix, process routings, and processing times for the four parts in
Problem 3. The FMS proposed to machine these parts will operate 20 hours per
day, 250 days per year. Assume system availability = 95%. Determine: (a) how
many servers at each station will be required to achieve an annual production
rate of 75,000 parts per year, and (b) the utilization of each workstation. (c)
What is the maximum possible annual production rate of the system if the
bottleneck station were to operate at 100% utilization?