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1. MEC3204 Production Engineering S2,2015
1
Faculty of Engineering and Surveying, University of Southern Queensland
MEC3204 – Production Engineering, S2, 2015
Assignment 1 – Marks 100/1000
Due: 04th
September 2015
INTRODUCTION
Work study
The initial stage (Figure 1) of manufacturing of cushion seats for stadiums &
public seating areas is the preparation of seat frames using hollow steel tubes
(Figure 2). There is an increased demand for seats but the factory is not able to
meet the present demand with the existing process set up. Due to this reason
the management decided that a quick Method Study should be carried out on
the initial stage of seat manufacturing for possible improvements of the
productivity in that section.
Present Method
(a) Equipment
1. Pipe Cutter -_Circular saw
Cut 4m long pipes to 500 mm long pieces and the ends of 500 mm parts
to 450
corners (Fig 2) .
2. Welding – electric Arc
Weld four cut 500 mm pipe pieces into a square shape (Fig2).
3. Bench Drill & Cleaning brush wheel
Drill two holes of 10 mm dia on each 500 mm pipe part. (8 holes on the
square frame)
4. Painting Equipment
Clean the surfaces of square pieces and paint the square piece
(b) Personnel
Six operators are employed on the process. Operator one (Ops1) picks up 10
pipes (12 kg/pipe and 6.5 m long) at a time from the main storage and

2. MEC3204 Production Engineering S2,2015
2
transports them in a wheeled trolley to a cutting station. He then helps
Operator two (Ops 2) to cut them in to 500m lengths (only 12 pcs from each
pipe due to the allowance for cutting tolerance). Operator two cuts all ten pipes
in to 500 mm pcs and then cuts two ends of each 500 mm long piece to 45 deg
corners (Refer Fig 2). When Operator two finishes cutting the ends of 60 pcs of
500 mm long (cut to 45 deg), Operator one then transfers 60 pcs in a trolley to
a welding station bin. Operator one pushes the empty trolley back to cutting
station and then returns to storage for next 10 pipes.
Ops 1 returns with the next load of 10 pipes and wait for Ops 2 to finish last 60
pcs. Then Ops 1 transports 60 pcs to a welding station bin and returns with the
empty bin and helps Ops2 to cut the pipes.
Operator 3 (Ops 3) welds the corners of the four pieces of 500mm long pipes
(corners cut to 45 deg) in to a square shape and puts them in the out bin
(trolley). When Ops 3 finishes 15 pcs (4 X 15pcs =60 pcs) of squares then Ops
3 signals Operator 4 (Ops 4) at the drilling & cleaning bench. Operator 4 pushes
an empty trolley to the welding station and takes finished squares in the out
trolley to drilling bench.
Operator 4 places each square frame in a drilling jig and drills two holes on each
leg (total 8 holes) of the square frame and Operator 5 (Ops 5) cleans the frame
using the cleaning wheel. When finished 15 pcs, Ops 4 transfers frames to the
inspection bench and returns with the empty trolley from the inspection bench.
Operator 6 (Ops 6) picks up frames from the inspection bench and paints the
frame. Finished frames are hanging on a wheel trolley. Each trolley can have
15 frames. Once finished Operator 6 pushes the trolleys to the drying area.

3. MEC3204 Production Engineering S2,2015
3
(c) Method of operation
The following flow process charts have been prepared and show the exact
methods and element times.
(i) Worker type, Operators 1
Chart begins – Operator 1 pickup pipes from the storage
Chart ends – Operator 1 returns to storage
Pick up ten pipes from the storage O 8.7 min
Push the trolley back to cutting station T 5 min
Transport finished 60 pcs (previous) to welding & return
With empty trolley T 2 mins
Help Operator 2 for cutting O 5 min
Wait until Operator 2 finish 60 pcs D
Transport finished 60 pcs to welding & return
With empty trolley T 2 mins
Return to storage for next 10 pipes T 3 mins
(ii) Worker type Operator 2
Chart begins – Operator 2 start cutting pipe
Chart ends – finish last 500 mm piece
Cut a 6.5 m long pipe into 12 X 500 mm pieces O 5 min
Cut two ends of 120 pcs to 45 deg corner O 32 min
Wait for next 10 pipes D ?

4. MEC3204 Production Engineering S2,2015
4
(iii) Worker type Operator 3
Chart begins – Receive 60 pcs and Operator 3 start welding 4 pcs
Chart ends – finish last 500 mm piece
Operator 3 pickup 4 pcs & place in the jig O 0.08 min
Weld corners & put in out trolley O 0.5 min
Repeat the procedure 15 times O
Wait for next lot D
(Each hour Operator 3 takes 5 mins break)
(iv) Worker type Operator 4 & 5
Chart begins – Receive 15 pcs and Operator 3 starts welding 4 pcs
Chart ends – finish last 500 mm piece
push empty trolley to welder T 0.03 min
pull the trolley with 15 frames T 0.03 min
fix one frame in jig and drill 8 holes O 0.7 min
Remove from the Jig polish the frame O 0.8 min
Put finish frame in out trolley O 0.01 min
Repeat procedure for 15 times O
Push out trolley to inspection desk &
Back with the empty trolley T 0.08 min
Wait for next lot D

5. MEC3204 Production Engineering S2,2015
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(v) Worker type Operator 6
Chart begins – Pick up inspected pcs from inspection desk
Chart ends –push the trolley to drying area
Operator 6 Pick up the frames from Inspection desk T 0.06 min
Hang one frame on painting hook O 0.01 min
Paint the frame (one at a time) O 0.3 min
Remove painted frame hang on the trolley T 0.01 min
Repeat the procedure until frames are finished O
Push the trolley to drying area T 0.3 min
Wait for the next lot D
(vi) Material Type
Chart begins – From the main storage
Chart ends – Drying area waiting for pick up to by assembly
Main storage S
Pick up 10 pipes and placed in a trolley O 8.7 min Ops 1
Transport to Cutter T 5 min Ops 1
Cutting into 120 pcs (10 pipes) O 5 min Ops 1 & 2
Cutting ends to 45deg corners O 32 m Ops 2
Transport to Welding station T 2 min Ops 1 (1
trips)
Weld in to squares O 17.4 min Ops 3
Transport for drilling T 0.06 min Ops 4(2
trips)
Drilling 8 holes/frame for 60 frames O (21 min) Ops4
Polishing frames O 24 min Ops5
Transport to Inspection Desk T 0.08 min Ops 4 (2
trips)
Inspection #

6. MEC3204 Production Engineering S2,2015
6
Transport to painting shop T 0.06 min Ops6 (2
trips)
Put on the painting hook (30 Nos) O 0.3 min Ops 6
Painting (30 Nos) O 9 min Ops 6
Put on drying trolley O 0.3 min Ops 6
Transport to drying area T 0.6 min Ops 6 (2
trips)
NOTATION:
Storage (S)
Operation (O)
Inspection (#)
Transport (T)
Temporary storage or delay (D)

7. MEC3204 Production Engineering S2,2015
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General Information:
a. The frame manufacturing section operates 7.30 am to 5.00 pm every
week day. It closes on Saturday and Sunday. Workers get 30 mins for
lunch break and 15 mins per break for the morning tea and the afternoon
tea.
b. Each worker has been trained in every work type and capable of working
in any work cell.
c. Management will consider any suggestion i.e. employing an additional
worker or adding a work cell but with the same existing type of
equipment. However, in this Study they only add an operator and/or a
work cell, if the additions can be strongly justified on the basis of
significantly increased productivity. No automation or improved material
handling equipment will be considered at this stage.
d. At the moment Ops 1, 2, 4, 5, are paid at the rate of $16.45/hr and Op3
receiving a higher rate $22.50/hr. No suggestions for increases of wages
or other additional payments will be considered by the management at
this stage.
e. The layout of the work cells may be changed except the painting and
drying stations. However, strictly no major constructions or change of
factory building layouts will be considered by the Management.
f. Management may consider a rotation of workers in operations on logical
manner quarterly, if justifiable on the human factors and workers
satisfaction (expected).
Your Task:
 Use relevant symbols for your charts, not the abbreviated notations such
as O, T, # etc
 You may estimate missing dimensions in Figure 1
 List all the assumptions with a short justification.

8. MEC3204 Production Engineering S2,2015
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(a) Present method:
I. Develop a flow process chart for each worker type, material type and
equipment type for present method. (10 Marks)
II. Develop multiple activity charts for Operators 1 to 6 and materials for the
present method. (10 Marks)
III. Determine actual time taken per finished frame using the present method
and estimate the total labour cost per finished frame. (10 Marks)
IV. Estimate present annual output of the frames based on 220 days/year (10
Marks)
(b) Critical analysis for improvements and development of a new method:
V. Briefly (not more than two A4 pages) discuss your suggestions (preferably
in point form) with a valid arguments based on logical and doable within
present constraints. Show your changes of factory floor lay out (if any)
graphically in neat sketches and calculation in clear steps with detail. You
may use additional page for a new floor layout. (20 Marks)
VI. Repeat I to III tasks for your proposed method. (24 Marks)
VII. Estimate the saved time, annual output and improved productivity. (10
Marks)
VIII. In a half A4 paper give an abstract of what you would do to improve the
productivity of this factory floor using $50,000 (or less) capital
improvement with a hope to recover it within 3 years based on real life
situation at present. (6 Marks)
Use standard (appropriate) chart types and analysis shown in the “Study Book”
Chapters 5,6,7 and 8. Please reference properly if you use other published
materials.

9. MEC3204 Production Engineering S2,2015
9
15 m
24m
5 m
3m
3m
4m
Pipes in Trolley
Output/Input trolleys
Cut pipe pcs & frames
Output/Input trolleys
Painted frames
2.8 m Openning
2.8mopenning
(Not to a scale)
Cutting Bench
Welding Bay
Drilling & Polishing Bench
Inspection Bench
Painting Bay
Main Storage about 20 m
away from this Bldg.
20m
Drying Area
Drying Area
Figure 1. Floor Plan (You are permitted to estimate missing distances)

10. MEC3204 Production Engineering S2,2015
10
500 mm
25mmID2.6mmthicksteelpipes
45 deg
Figure 2 Cut pcs. and a frame