INDUSTRIAL ENGINEERING 4023 : ADVANCED MANUFACTURING SYSTEMS

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Please complete assignment based on rubric provided. 3 different steps Industrial Engineering 4023: Advanced Manufacturing Systems *Must be fluent/native english speaker as professor takes points off for grammar/spelling errors* *MUST be finished by 3/2* *CANNOT be plagiarized* COMPLETE THE FOLLOWING BASED ON PROVIDED INFORMATION IN DOC AND ALSO N=2700, X=7. Takt time Current State map Timeline Information flow Inventory in Timeline and Triangle Kaizen Map Future State Map

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East Carolina University College of Engineering and Technology Department of Technology Systems IENG 4023 (Sections 601 and 602) Advanced Manufacturing Systems, Spring 2021 HW Assignment # 2 Team based Total Marks: 70 Assigning Date: January 18, 2021 Last Date and Time for submission: March 07, 2021 by 11:59 PM Note: You may discuss assignment questions with your friend(s) directly or through Course Related Discussion Thread, but you need to submit your team’s own unique copy of solution in the assignment page. The assignment will be marked zero for the student teams who makes copy or who is providing their solution for copying. Please write your team/Group number, names, and assignment # at every page. You may ask your friend about their final result and/or some explanation about your confusion, but you should not ask another team to provide or post their descriptive answer or computation steps for any part or total question in the discussion board. You will also not write descriptive or computation steps for your friends. Explain in detail your answers for descriptive type questions. Write your assumptions (if any) and show detailed calculations at each step for arriving at the answers to the computational type of questions. You will not get any point for only writing the answers to the computational type of problems. You are encouraged to enrich your answers to the descriptive questions by providing information from reference sources. In the case you use any materials from reference sources, please include details of the references. (It is a Team/group based assignment. Solve the assignment in your class project group) Please note: values of N and X are given based on Group # below: : 1. (Points 45) A bolt manufacturing factory ships N number of bolts per X days a week. There are 15 process steps described below to realize the bolt and ship to customer: Assume the Factory does not have any breaks during the day. 2. Step 1: Blanking, CT: 0.75 Sec, CO: 6 hours, 1 operator; MC reliability 100%, scrap rate 0.05% Step 2: Necking, CT: 8.57 Sec, CO: 1.5 hours, 1operator; MC reliability 100%, scrap rate 0.05% Step 3: shape Head, CT: 10 Sec, CO: 0.5 hours, 1operator; MC reliability 100%, scrap rate 0.05% Step 4: Pickle and Dubois, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0% Step 5: Carburize and induction, CT: 2.7 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 1% Step 6: Receiving, CT: 0.01 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05% Step 7: Metrology Lab, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05% Step 8: Roll thread, CT: 0.857 Sec, CO: 2 hours, 1operator; MC reliability 100%, scrap 0% Step 9: Phosphorous and Oil, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0% Step 10: Re-Roll and Box, CT: 0.857 Sec, CO: 2 hours, 1operator; MC reliability 100%, scrap 0% Step 11: 100% sort, CT: 5 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05% Step 12: Salt Spray, CT: 0.02 Sec, CO: 10 hours, 1operator; MC reliability 100%, scrap 0.05% Step 13: Doc final, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05% Step 14: Chemical and physical certification, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05% Step 15: Label & ship, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05% Inventory information: Before: Step1 500 coils, equivalent to 5 days bolts requirements; Step2 38,400 pieces; Step3 3360 pieces; Step4 2880; pieces; Step5 4500 pieces; Step6 1066 pieces; Step7 6000 pieces; Step8 4500 pieces; Step9 1243 pieces; Step10 1243 pieces; Step11 1450 pieces; Step12 7500pieces; Step13 4500pieces; Step14 4500pieces; Step15 3000pieces; and at the shipment store just after step 15: 7500 pieces Rubric Compute takt time 2 points; : Prepare current state value Stream map including time line and information flow 9 points, Now show the inventory lead time in number of days by your computation: 4 points; plan improvement in a copy of current state map (improvement planning Map using kaizen lightening sparks 10 points; prepare the future state based on your Groups effort showing all required information for a value stream 15 ( it must be unique for your team based on the judgment and knowledge of your team) N=2700, X=7 days for the remaining Groups (3 and 5). Consider Only one shift production in a day with no breaks. Rubric Max Obtained Takt time 2 Current State map 9 Timeline 4 Information flow 2 Inventory in Timeline and Triangle 3   Kaizen Map 10   Future State Map 15   Total 45   3. (Points 25) Follow the Lecture 4 -Process Value Mapping for preparing the current State Process Value map analysis based on the Process Block Diagram shown below. Now prepare improved future state map, and matrix for future state. Ref: Taken from one of the student project report of spring 2010 Rubric Max Pt Obtained point Current State Process value map 8 Current State Analysis Matrix 7   Proposed Future State MAP 12   Future State Matrix 8   Total 35   Description for the process steps is given for your study to prepare the current State and finally Future State Process value map for improving the process. (Follow all the steps in: Lecture 4 and Narrations of the problem) Patient Care Delivery at Rex Healthcare The journey of general patient care delivery begins with the arrival of the non-emergent patient at the admissions/check-in area. The admissions/check-in area is usually filled with patients registering as well as waiting on rooms/beds in their assigned units. A waiting time of 90 minutes is not unusual for a room to become ready after the arrival of a patient at the hospital. After the bed control unit of patient admissions secures a room for the patient in the medical/surgical unit, a patient transporter is summoned to transport the patient to the assigned medical unit. Typically, the patient is transported by wheelchair, and this journey takes about 10 minutes from the admissions/check-in area to the medical/surgical unit. Upon arrival at the medical/surgical unit, the patient is wheeled into the assigned room or may be redirected by a nurse or unit secretary, if the assigned room has been changed. After arrival in the room, the patient is welcomed by a nurse who verifies the identity of the patient and that he or she is in the correct room. This area check-in can be followed by a delay of up to 30 minutes before a nurse does an orientation of about 15 minutes. Another delay of 20 minutes usually follows before a nurse takes the patient’s vital signs and assists the patient in changing clothes. In about 30 minutes, a laboratory technician arrives to carefully draw blood from the patient which takes about 10 minutes. About 40 minutes later, the first ancillary department arrives to administer therapy such as respiratory care which last about 15 minutes. Thirty minutes later, the patient is favored with a meal from the food and nutrition department which is delivered quickly, and roughly allots about 30 minutes for the patient to consume the meal before the meal tray is retrieved. Approximately 40 minutes after the meal, the nurse arrives to deliver medication to the patient. Depending on the route of delivery, the medication administration could take up to 6 minutes. About 20 minutes later, the second ancillary service, a radiology technician, arrives to perform an x-ray on the afflicted body part. The x-ray is done in the patient’s room to expedite time and eliminate patient transport, but still takes about 20 minutes for setup and positioning. Around 40 minutes later, a doctor makes a visit to the patient for a 15-minute evaluation, and treatment discussion. Thirty minutes later, a case worker or social worker from that department shows up to discuss personal concerns, and care plans for the patient once he or she goes home. This discussion typically takes about 20 minutes. Twenty minutes later, the food and nutrition department arrive with a meal to be consumed by the patient in 30 or so minutes. About 30 minutes after the meal, a nurse or nursing assistant arrives at the patient’s room to record the patient’s vital signs. Twenty minutes after the patient’s vital signs are recorded, a nurse administers medication to the patient lasting 6 minutes in duration. In about 30 minutes, the ancillary service of physical therapy begins a 30-minute session with the patient. Thirty minutes later, a physician enters the patient’s room to do an assessment and update the patient on his or her course of treatment. Of course, this cycle of patient services would be completed over each day of the patient’s stay in the hospital. To forgo repetitiveness, I will expedite to the point where the patient has been cleared for discharge. Usually, 60 minutes after a patient discharge notification, the nurse brings the patient the news, and takes about 20 minutes to go over the discharge instructions for the patient’s care at home. Sometimes, there can be a longer delay in presenting the discharge instructions if a family member needs to be present for more complete understanding of the discharge instructions. Once the discharge instructions are completed, it is not uncommon to take 90 minutes or more to clear the discharge paperwork and obtain a patient transporter. Upon arrival, the patient transporter assists the patient in gathering her or his belongings and transports the patient to the hospital exit via wheelchair. The patient transporter takes about 15 minutes for this duty. The patient’s care is highly dependent upon clinical professionals who deliver care directly to the patient who usually receives hospital care within the hospital room. There are several clinicians displayed in this project scenario. The patient transporter is an individual who is dispatched by the hospital bed control department to physically move the patient between locations in the hospital. Transporters are often centrally located near the patient admissions area for quick availability in transporting patients upon clearance from bed control. The current system of transporting patients is akin to FIFO for the transporters. Occasionally, during high admissions periods, all transporters will be occupied leaving no immediate availability to move newly admitted patients to their assigned hospital unit locations and rooms. Nurse and nurse assistants play vital roles in the processing of patients during their hospital stays. Nurses and nurse assistants are typically assigned to a set of patients. In medical-surgical areas, a nurse may have up to 12 patients assigned, thus, some minor delays in delivering nursing services may be experienced by those patients. Oftentimes, another available nurse may assist in preventing extraordinary delays in patient nursing care. Dietary technicians are dispatched from the hospital kitchen during set blocks of time for meals delivery to patients. Today, patients can select their meals allowed and arrival times via an in-room kiosk or the room telephone. The dietary technician allows about 30 minutes for a patient to consume a meal before she or he returns to the patient’s room to retrieve the meal tray. X-ray technicians are centrally located in the radiology department and are dispatched on an as needed basis to patients’ rooms. Portable x-ray equipment is positioned within the medical-surgical area. The x-ray technician arrives in the area, moves the portable x-ray equipment (on an electrically motorized dolly) to the patient’s room, and performs the x-ray on the body part as ordered. At times, an x-ray technician may request assistance from the nursing staff to position an immobile patient. Respiratory therapists are assigned areas of the hospital according to their experience and comfort levels working certain areas. The respiratory therapist assigned to the medical-surgical area usually only has that area of responsibility. Other therapists may help should the assigned respiratory therapist need assistance. Physical therapists are dispatched from a location in the same general region as the medical-surgical area. The proximity of the physical therapists to the medical-surgical area is to expedite PT services to this area of highest demand. Laboratory technicians/phlebotomists are dispatched from the main hospital lab or the auxiliary lab located one floor below which is nearest the intensive care units. The laboratory technicians are dispatched in a FIFO manner from their locations and are known for quick efficient responsiveness. Although these different, clinicians have multiple patients to provide service, careful scheduling can provide excellent patient services with few major delays in those services. The patient processing times shown on the value stream maps account for the actual patient service as rendered and not for travel times of the clinicians providing service. Such clinician travel times would be extremely difficult to calculate, and measure. Block Diagram Rex Healthcare General Medical/Surgical Patient Servicng Value Stream Mapping Analysis Patients in queue waiting forgeneral medical/surgical Medical/surgical area check-in of patient upon arrivalNursing evaluation and patient area orientationPatient vital signs measured bynurse or nurse assistantBlood sampledrawn from patient for laboratory evaluation.Ancillary service performed. i.e. respiratory care therapyDischarge planning with patient by socialservicesclinician or nurse.Ancillary service performed. i.e. social services.Physician visit, includes vital signs, brief physical check on patient.Ancillary service performed. i.e. radiology/xray.Medications delivered by pharmacy and administered by nurse.Nutrition/meal service administered.Nutrition/meal service administered.Patient vital signs measured bynurse or nurse assistantMedications delivered by pharmacy and administered by nurse.Ancillary service performed. i.e. physical therapy.Physician visit, includes vital signs, brief physical check on patient.Patients in queue forDischarge from hospital.Patient discharged from hospital to home.Admissions/hospitalcheck-in East Carolina University College of Engineering and Technology Department of Technology Systems IENG 4023 ( Sections 601 and 602 ) Advanced Manufacturing Systems, Spring 20 21 HW Assignment # 2 Team based Total Marks: 70 Assigning Date: Janu ary 1 8 , 20 21 Last Date and Time for submission : March 0 7 , 20 2 1 by 1 1 : 59 PM Note : You may discuss assignment questions with your friend(s) directly or through Course Related Discussion Threa d , but you need to submit your team’s own unique copy of solution in th e assignment page. The assignment will be marked zero for the student teams who makes copy or who is providing their solution for copying. Please write your team /Group number, name s , and assignment # at every page. You may ask your friend about their final result and/or some explanation about your confusion, but you should not ask another team to provide or post their descriptive answer or computation steps for any part or total question in the discussion board. You will also not write descriptive or computation steps for your friends. Explain in detail your answers for descriptive type questions. Write your assumptions (if any) and show detailed calculations at each step for arriving at the answers to the computational type of questions. You will not get any point for only writing the answers to the computational type of problems. You are encouraged to enrich your answers to the descriptive questions by providing information from reference sources. In the case you use any materials from reference sou rces , please include details of the references. (It is a Team /group based assignment. Solve the assignment in your class project group ) Please note: values of N and X are given based on Group # below: : 1. (Points 45) A bolt manufacturing factory ships N number of bolts per X days a week . There are 15 process steps described below to realize the bolt and ship to customer : Assume the Factory does not have any breaks during the day. 2. Step 1: Blanking , CT: 0.75 Sec, CO: 6 hours, 1 operator; MC reliability 100%, scrap rate 0.05 % Step 2: Necking , CT: 8.57 Sec , CO: 1.5 hours, 1 operator; MC reliability 100%, scrap rate 0.05 % Step 3: shape Head, CT : 10 Sec , CO: 0.5 hours, 1 operator; MC reliability 100%, scrap rate 0 .05 % Step 4: Pickle and Dubois, CT : 0.02 Sec, CO: 0 hours, 1 operator; MC reliability 100%, scrap 0 % Step 5: Carburize and induction, CT : 2.7 Sec, CO: 0 hours, 1 operator; MC reliability 100%, scrap 1 % Step 6: Receiving, CT : 0.01 Sec, CO: 0 hours, 1 operator; MC r eliability 100%, scrap 0.05 % Step 7: Metrology Lab, CT : 0.02 Sec, CO: 0 hours, 1 operator; MC reliability 100%, scrap 0.05 % Step 8: Roll thread , CT: 0.857 Sec, CO: 2 hours, 1 operator; MC reliability 100%, scrap 0 % Step 9: Phosphorous and Oil, CT : 0.02 Sec, CO: 0 hours, 1 operator; MC reliability 100%, scrap 0 % Step 10 : Re - Roll and Box, CT: 0.857 Sec, CO: 2 hours, 1 operator; MC reliability 100%, scrap 0 % Step 11: 100% sort, CT: 5 Sec, CO: 0 hours, 1 operator; MC reliability 100%, scrap 0.05 % Step 12: Salt Spray, CT: 0.02 Sec, CO: 10 hours, 1 operator; MC reliability 100%, scrap 0.05 % Step 13: Doc final, CT: 0.02 Sec, CO: 0 hours, 1 operator; MC reliability 100%, scrap 0.05 % Step 14: Chemical and physical certification, CT: 0.02 Sec, CO: 0 hours, 1 operator; MC reliability 100%, scrap 0.05 % Step 15: Label & ship, CT: 0.02 Sec, CO: 0 hours, 1 operator; MC reliability 100%, scrap 0.05 % East Carolina University College of Engineering and Technology Department of Technology Systems IENG 4023 (Sections 601 and 602) Advanced Manufacturing Systems, Spring 2021 HW Assignment # 2 Team based Total Marks: 70 Assigning Date: January 18, 2021 Last Date and Time for submission: March 07, 2021 by 11:59 PM Note: You may discuss assignment questions with your friend(s) directly or through Course Related Discussion Thread, but you need to submit your team’s own unique copy of solution in the assignment page. The assignment will be marked zero for the student teams who makes copy or who is providing their solution for copying. Please write your team/Group number, names, and assignment # at every page. You may ask your friend about their final result and/or some explanation about your confusion, but you should not ask another team to provide or post their descriptive answer or computation steps for any part or total question in the discussion board. You will also not write descriptive or computation steps for your friends. Explain in detail your answers for descriptive type questions. Write your assumptions (if any) and show detailed calculations at each step for arriving at the answers to the computational type of questions. You will not get any point for only writing the answers to the computational type of problems. You are encouraged to enrich your answers to the descriptive questions by providing information from reference sources. In the case you use any materials from reference sources, please include details of the references. (It is a Team/group based assignment. Solve the assignment in your class project group) Please note: values of N and X are given based on Group # below: : 1. (Points 45) A bolt manufacturing factory ships N number of bolts per X days a week. There are 15 process steps described below to realize the bolt and ship to customer: Assume the Factory does not have any breaks during the day. 2. Step 1: Blanking, CT: 0.75 Sec, CO: 6 hours, 1 operator; MC reliability 100%, scrap rate 0.05% Step 2: Necking, CT: 8.57 Sec, CO: 1.5 hours, 1operator; MC reliability 100%, scrap rate 0.05% Step 3: shape Head, CT: 10 Sec, CO: 0.5 hours, 1operator; MC reliability 100%, scrap rate 0.05% Step 4: Pickle and Dubois, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0% Step 5: Carburize and induction, CT: 2.7 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 1% Step 6: Receiving, CT: 0.01 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05% Step 7: Metrology Lab, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05% Step 8: Roll thread, CT: 0.857 Sec, CO: 2 hours, 1operator; MC reliability 100%, scrap 0% Step 9: Phosphorous and Oil, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0% Step 10: Re-Roll and Box, CT: 0.857 Sec, CO: 2 hours, 1operator; MC reliability 100%, scrap 0% Step 11: 100% sort, CT: 5 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05% Step 12: Salt Spray, CT: 0.02 Sec, CO: 10 hours, 1operator; MC reliability 100%, scrap 0.05% Step 13: Doc final, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05% Step 14: Chemical and physical certification, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05% Step 15: Label & ship, CT: 0.02 Sec, CO: 0 hours, 1operator; MC reliability 100%, scrap 0.05%

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