PDE4905: A Semi­?Skilled Operator to a CNC Lathe Loads Rods of 60mm – Engineering Simulation Assessment Answer

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SUBJECT CODE: PDE4905
Engineering Simulation Assessment Answer
TASK:
Problem
A semi-­?skilled operator to a CNC lathe loads rods of 60mm dia, 1 m length. This takes no less than 1 min,  no greater than 3 mins, with a mode of 1.5 mins. The rod is machined into spindles 95 mm long with 3  mm part-­?off (3 mins each) plus an off-­?cut, which is pushed to scrap. This takes 10 mins to complete  After 30 rods have been machined, the tools are changed and the machine cleared of swarf (6 – 10  mins).
The spindles are placed in a bin that can contain max 50. The operator loads them to a grinder for the main shaft to be ground (1.0 min) and unloads then to a bin of max. 50. Loading and unloading take 0.25 – 0.5 min. Every 10th spindle is pushed to a buffer for inspection, the rest are pushed to SHIP.  The operator inspects every 10th spindle (2 – 4.5 min) at an inspection bench. There is an 80% chance  that a spindle will be at its upper tolerance limit after 120 have been inspected  If this is the case:

the spindle is returned to the spindle bin for re-­?grinding if there is capacity. If not it is scrapped.

the Grinder is reset and the wheel may be dressed.

This takes a min of 1.5 mins and max of 5 mins with a mode of 2 mins.

Testing
Run the model for one day (24 hrs = 1440 mins). How many spindles are produced and scrapped?
Now set the Warmup to 200 mins and run the model for 1640 mins. The statistics are reset after the warm-up time so we can see what the daily production rate is during steady state. Fill out the following table:
Engineering Assessment Answer
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