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Answer :
The total number of cycles required to complete 300 parts is:300 / Q = 300 / 1 = 300So, the total time required to complete the batch is: Time = 3.0 + (300 x (4.50 + t1 + t2)) min
(a) Calculation of minimum cost per piece:
Cost equation: CT = ((TO x LC) / R) + (TL x Lf) + ((TO x Tc) / Q)
Given data: TO = $39/hr, LC = 1 min, TL = $2/tool, Lf = 2, Tc = 1 min, Q = 1 piece per run
Calculation of production rate (R): R = 1 / ((0.007 x 2 x 0.100) x (1/rev)) = 7.14 pieces per min
Substituting values into the cost equation: CT = ((39 x 1) / 7.14) + (2 x 2) + ((39 x 1) / 1) = $8.88
The minimum cost per piece is $8.88, which occurs at a cutting speed of 375 ft/min.
(b) Calculation of average time required for one production cycle:
Element times: Load part and start cycle time = 1.00 min, Positioning tool for first pass time = 0.10 min, Repositioning tool for second pass time = 0.4 min, Tool change time = 1.00 min, Unload part and place in tote pan time = 1.00 min
Turning time calculation: t = (L x N) / (f x a x d)
Given: L = 10 in, N = 2, f = 0.007 in/rev, a = 0.100 in, d = 3.00 in
First pass turning time (t1): t1 = (10 x 2) / (0.007 x 0.100 x 3.00) = 381.6 rev
The total time for one production cycle: 1.00 + 0.10 + t1 + 0.4 + t2 + 1.00 + 1.00 + 1.00 = 4.50 + t1 + t2 min
(c) Calculation of the cost of the production cycle:
Given data: TO = $39/hr, TL = $2/tool, Lf = 2, Tc = 1.00 min
Material cost calculation: Cp and CM values are not provided, so the material cost cannot be determined.
The cost of the production cycle: CT = ((TO x LC) / R) + (TL x Lf) + ((TO x Tc) / Q) + CM (CM cannot be calculated without Cp)
(d) Calculation of time to complete the batch:
Given: Setup time = 3.0 hours, Batch size = 300 parts
Total time to complete one production cycle: 4.50 + t1 + t2 min
Total number of cycles required: 300 / Q = 300 / 1 = 300
Total time to complete the batch: Time = 3.0 + (300 x (4.50 + t1 + t2)) min
The total number of cycles required to complete 300 parts is:300 / Q = 300 / 1 = 300So, the total time required to complete the batch is: Time = 3.0 + (300 x (4.50 + t1 + t2)) min
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