Solve the LP given below by hand using the full tableau showing all steps.

Question 1 a) Define JIT and Lean Manufacturing and contrast the similarities and differences between the two. Discuss why the 'Traditional approach' is more intuitive and what approaches are needed to move toward a JIT scenario? b) Critically appraise five of the nine Just in Time (JIT) techniques e.g. reduction of set up time, TPM etc. highlighting what they are and how they would be implemented c) Describe a tool or technique which can be used to analyse and improve the performance of manufacturing systems e.g. Rank-order clustering, Ishikawa diagrams, Value Stream Mapping Root cause analysis, Pareto Analysis etc. Explain the basic principle behind the technique, how it would be applied and the potential benefits/inhibitors to implementation.

Question 2 'Smoothtools' manufacturing company want to enter the 'woodworking tools' market and one of the first products it has decided to manufacture is a general purpose smoothing plane. (See Figure Q2- parts view). After 'reverse engineering' the wood plane, the planning department have arrived at a build sequence and timings for each task which is shown in Table Q2(a). Furthermore, the marketing department at 'Smoothtools' have produced a sales forecast for the new planes which is given in Table Q2(b). The plant is expected to have a work pattern of 40 hours week, 48 weeks per year. Assuming a Product layout (Long thin) arrangement, determine the following information for the 1st quarter of production: a) The required cycle time and the theoretical minimum number of people required to assemble the products b) The 'line design'. c) The actual number of people required to manufacture/assemble the product based on your design and what would be the balance loss and estimated output for this arrangement? d) If a 'short fat' layout is used in the 1st quarter, how many people would be required to assemble the products? What is the balance loss and potential output for this arrangement? e) Considering the two options. Which layout is best suited to meet the demand in 4th quarter and why? f) What are the advantages and disadvantages of both 'long thin' and 'short fat' layouts?

Question 1 a) Define JIT and Lean Manufacturing and contrast the similarities and differences between the two. Discuss why the 'Traditional approach' is more intuitive and what approaches are needed to move toward a JIT scenario? b) Critically appraise five of the nine Just in Time (JIT) techniques e.g. reduction of set up time, TPM etc. highlighting what they are and how they would be implemented c) Describe a tool or technique which can be used to analyse and improve the performance of manufacturing systems e.g. Rank-order clustering, Ishikawa diagrams, Value Stream Mapping Root cause analysis, Pareto Analysis etc. Explain the basic principle behind the technique, how it would be applied and the potential benefits/inhibitors to implementation.

Question 2 *Smoothtools' manufacturing company want to enter the woodworking tools' market and one of the first products it has decided to manufacture is a general purpose smoothing plane. (See Figure Q2- parts view). After 'reverse engineering' the wood plane, the planning department have arrived at a build sequence and timings for each task which is shown in Table Q2(a). Furthermore, the marketing department at 'Smoothtools' have produced a sales forecast for the new planes which is given in Table Q2(b). The plant is expected to have a work pattern of 40 hours week, 48 weeks per year. Assuming a Product layout (Long thin) arrangement, determine the following information for the 1st quarter of production: a) The required cycle time and the theoretical minimum number of people required to assemble the products b) The 'line design'. c) The actual number of people required to manufacture/assemble the product based on your design and what would be the balance loss and estimated output for this arrangement? d) If a 'short fat' layout is used in the 1st quarter, how many people would be required to assemble the products? What is the balance loss and potential output for this arrangement? e) Considering the two options. Which layout is best suited to meet the demand in 4th quarter and why? f) What are the advantages and disadvantages of both 'long thin' and 'short fat' layouts?

What is an additive manufacturing (AM) or additive layer manufacturing (ALM) process?

* Describe the part: Part name - function original material - dimensions and weight. Use the photos you took during the lab session to improve show your hands-on work.

* What are the advantages and disadvantages of FDM. advantages: (fast speed.helps, and allows to print large objects.low cost)

Introduction to Additive Manufacturing • What is an additive manufacturing (AM) or additive layer manufacturing (ALM) process? • What are the available AM technologies? • Focus on FDM additive technologies (the one we use in the lab) • Subtitles could include: model generation - slicing - printing - possible defects - post- processing - applications - famous brands - the brand you used in the lab material range - price range - market size - possible future applications - can it be used in the International Space Station? • What are the advantages and disadvantages of FDM?

Assessment Task Writeaprojectreporttoinclude the following elements: Element 1: Analyze the product requirements PC1 Identify the problem and produce a design brief PC2 Research into the problem and identify the requirements and constraints. (Consider such factors as: Function, performance, the environment, aesthetics, ergonomics, safety, the customer, the culture, the law, Size, costs, materials, quantity, time and manufacturing resources. PC3 Produce a detailed specification of requirements (Product Design Specification) Element 2: Design for manufacture PC1 Sketch and annotate a range of creative ideas and for the product. PC2 Model the best ideas in CAD and evaluate these ideas against design specifications. PC3 Develop the final detailed design, including engineering drawings and diagrams to allow manufacture of the product. Element 3: Plan for manufacture PC1 Choose the sequence of activities to complete manufacture within in the required timeframe. PC2 Select industrially accepted planning tools and techniques and use these to plan activities in detail. (e.g. Gantt charts & activity planning sheets) PC3 Evaluate the plan for accuracy, detail, clarity and conformance to instructions and requirements. PC4 Modify the plan as necessary to overcome problems, unforeseen difficulties or developments that occur as work progresses. Element 4: Complete practical work PC1 Identify and prepare a suitable work area for manufacture of a prototype PC2 Interpret drawings and job requirements to select and prepare appropriate tools, equipment, materials and parts. PC3 Complete practical work safely and skilfully as planned to meet the design requirements. PC4 Test and evaluate the completed product against design requirements and modify, repair or repeat as necessary. PC5 Maintain the work area clean, tidy and ready for practical activities. (Tools, equipment and unused materials are returned to appropriate storage areas.) Element 5: Prepare a written project report PC1 Write a formal project report outlining the project stages in a logical order. Including the development of the design brief, the product design specification, design work, planning, and manufacture and testing. PC2 Describe the processes undertaken within the report, apply correct technical terms or units and use appropriate technical descriptions to reference diagrams, graphs, tables and equations. PC3 Show the completed prototype and compare this with the original design brief and specifications. PC4 Discuss areas for improvement in design and planning for future manufacture make recommendations for further development. PC5 Discuss the environmental impact of the project and suggest how this could be improved, considering raw materials, power consumption, pollution, waste etc. PC6 List books and sources of research as recommended further reading and reference authors when text or graphics is copied from any published source. Footer