Engineering Work Systems and Process Planning – Engineering Assignment Help

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Assignment Task :
EWP115C Assignment 17 February 2021 
A company produces machinery for industry. Many of the company’s products are  made in large quantities. This case problem deals with the mechanism plate for one of  these machinery products, shown in Figure 1(a). The mechanism plate is a major part  in the machine, serving as the backbone of the product. Most of the internal components  and subassemblies are fastened to this plate. In the finished product, the plate is  completely enclosed within the machine. The mechanism plate is the most expensive  part in the product and is the source of numerous quality problems as well. Similar  mechanism plates are used on many of the products, and their methods of production  are similar, so any improvements made to the subject plate will apply to the other plates  as well. As is typical in batch production, the manufacturing lead time of the mechanism  plate (time between release of the order and its completion) is quite long. Since other  parts are being processed at the same time in the plant, there are delays in front of each  production station as batches of mechanism plates wait their turn in the queues at these  stations. Mechanism plates take an average of 18 weeks to complete, once a production  order has been released. No information is available about how this time is distributed  among the different production steps. In addition, the castings may remain in the  warehouse prior to production for as much as 4 months. The following description  summarizes the sequence of steps used to fabricate the mechanism plate. Figure 2(a)  and (b) show floor layouts for the two stories of the factory building. Key areas and  departments relating to the mechanism plate production are indicated in the description  and on the floor layouts by numbers in parentheses. The mechanism plate is a sand  casting, supplied by a foundry located 6 meters away. It is made of cast iron and is very  heavy, constituting fully one-third the total weight of the product. The designer selected  cast iron because of its inherent rigidity and vibration damping characteristics. However, because it is a large flat part, the casting is subject to warping. The castings  are shipped to the company in batches of 50 to 100 units and inspected twice:(1) prior  to being stored in the plant warehouse and (2) when an order is placed for their release  to production. Production lot sizes are usually 5 to 10 parts. When the castings are  picked from the warehouse for an order, the first step is to send them to a local firm (5 
miles away) that specializes in sand blasting (which the company is not currently set  up to do). This treatment dislodges any sand imbedded in the surface that is left over  from the mold, removes rust that has occurred during storage, and smooths the surface.  The plates are then returned to the company warehouse. The parts are then processed  through a series of machining operations, the first and second of which are in the milling  department (3). The first milling operation is face milling to make one side of the plate  flat and smooth to accept the components that are to be attached. This is accomplished  in one setup on a large milling machine in the mill department. The second milling  requires a separate setup, and this operation makes the edges of the casting smooth and  straight. As the second milling operation is completed on each part, it is moved  individually to the chemical cleaning department (4) to be cleaned and pickled. The  cleaning is performed by human workers using cloth wipers soaked with chemical  solvents. The purpose of the cleaning is to remove cutting fluids from machining. Pickling is then performed in open tanks filled with relatively dilute acid which etches  the cast iron. The pickling brightens the surface texture of the machined surface of the  casting. Owing to the size of the casting, each part must be separately dipped into the  tank. The parts are then individually returned back to the machining area (drilling  department) to reconstitute the batch. The next step involves a series of hole drilling  operations in the drilling department (5). These holes are used to attach the various  brackets and components to the plate. This is performed on four different upright drill  presses, organized according to drill size. There are four different hole sizes in the plate. After drilling, two of the hole sizes are tapped in the same department (5), using two  additional drill presses. After drilling and tapping, the plates are returned to the cleaning  department (4) for cleaning and pickling. Again, they must be dipped separately and  moved individually to a temporary storage area (6) near the assembly department (9).  The plates are stored in the temporary storage area (6) until the other components that  are to be assembled have been collected. When all of the components have been  collected, the mechanism plate is sent to the painting department (7). The painting is  needed to provide a protective coating and for appearance reasons. The operation is  performed by human workers using paintbrushes to work the paint into the rough  texture of the sand cast surface. Two coats are applied in this way, with a five-hour low  temperature baking operation following each coating. The baking ovens are located in  the heat treatment department (8) at the rear of the factory. As many as five plates can  be baked at one time. After the final bake, the mechanism plates re-join the other  components in the temporary storage area (6). A “kit” of components is then made up,
which consists of one mechanism plate and a set of all the components that are to be  assembled to it. The kit is then sent to the assembly department (9), where the subassembly is completed. A total of 75 parts, including fasteners, are attached to the  plate. Each mechanism plate subassembly is put together at a single workstation. When  finished, it is put back into temporary storage (6) to await final assembly into the  machinery product.  
Milled
 
Elevator Aside
Elevator
 
PART A 
Assignment: 
Section 1 [25] Develop a cause and effect diagram that identifies the possible causes of the problem  stated in the above scenario. 
Section 2 [35] (a) Construct a flow diagram of the path followed by the mechanism plate during its  manufacture. (15) (b) Develop a list of possible improvements that might be made in the production of  the mechanism plate. (5) (c) Develop a proposed improved method based on your answers to (a)and (b), and  document your proposed new method by means of a flow process chart. Show how  this method is an improvement over the current method. (15) 
Section 3 [20] Consider the issue of plant layout in more extensively What changes in the overall  layout of the plant would you make to improve the efficiency of mechanism plate  production?
PART B
A factory has 10 departments, all of which have quality problems leading to delays in  shipping products to customers. A breakdown of the number of quality problems for  each department (listed alphabetically) is as follows: (1) assembly, 16; (2) final  packaging, 9; (3) finishing,37;(4) forging,73;(5) foundry,362;(6) machine shop,294;(7)  plastic molding,120;(8) receiving inspection,124;(9) sheet metalworking,86; and (10)  tool-making,42. 
(a) Construct a Pareto chart for this data.
(b) Assuming that all quality problems are of equal value, in which department would  you start to take corrective action to reduce the quality problems?
 
 
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