IE 4351 5357 Homework 8 Due April 15 2021 1 12 pts The definition of material handling provided in class includes providing the right amount of the right material in the right place at the right time in the right sequence in the right condition in the right orientation and at the right cost by using the right methods The Just in Time system addresses which of these rights Choose all that apply from the list below and briefly explain why they apply Amount Cost Condition Time Material Methods Orientation Sequence Place 2 12 pts Suppose you are the IE in charge of designing the MH system for an automotive assembly line You are considering two main design options The first will use a large conveyor that pulls cars through the entire assembly line as parts are placed on the cars The second will use AGVs similar to the truck example that we saw in the slides Discuss some of the advantages and disadvantages of each design and then discuss what might motivate you to choose one versus the other 3 12 pts What are some of the functions that Material Handling Systems provide in addition to material transportation Explain briefly 4 12 pts Explain in your own words what is meant by the unit load concept Why is the unit load concept important 5 20 pts Analyze the following vaccine capacity problem The packaged volume of single dose vaccines is given in the table below At a given location you need to have 11000 doses of each vaccine type The location you are analyzing uses refrigerators with storage compartment dimensions of 24 inches by 20 inches by 18 inches Assuming all vaccines are only stored in the refrigerator how many refrigerators do you need Fully justify your answer Vaccine Name DTP DTP HepB Hib Measles Oral Polio Tetanus Toxoid Tuberculosis Yellow Fever Packaged volume in cm3 3 9 7 3 5 1 3 1 2 2 5 6 12 pts At the MSA site in Cranberry they have chosen to receive all of their cardboard boxes used for test devices from their suppliers already constructed as opposed to receiving flat cardboard sheets sized and perforated as needed and constructing the boxes themselves These boxes are on average 4 8 inches long 2 4 1 inches high and 3 6 inches wide Discuss some of the pros and cons of using this strategy concerning cardboard boxes 7 20 pts MedTech is a manufacturer of disposable syringes used in the medical industry After the disposable syringes are manufactured and packaged there is an FDA requirement that the syringes be sterilized before they can be shipped from MedTech s facility The sterilization occurs in a large chamber and currently has a 12 hour cycle time including the time to load and unload the chamber MedTech currently has 3 sterilization chambers that have an average uptime of 98 The diagram below shows how pallets of syringes are loaded into the sterilization chamber The pallets are 48 inches by 54 inches and it takes about 10 minutes to load unload the pallets into out of the chamber The outer dimensions of the chamber are 14 feet by 28 feet and the usable area of the chamber that can hold pallets is 10 feet wide and 21 5 feet long MedTech currently runs the sterilization operation 24 hours a day 7 days a week 54 48 10 21 5 484 MedTech s current production schedule requires them to sterilize 300 pallets per week In the next year MedTech sees that increasing to 340 350 per week in two years to 350 375 per week and in three years to 380 400 per week In order to obtain increased sterilization capacity MedTech is considering the following options i Change the sterilization gas that they use in order to reduce the cycle time to 9 hours Changes to the equipment due to the gas conversion would cost 362 000 over the next 2 years Annual sterilization gas costs for the new gas would be roughly equal to the gas costs for the current sterilization gas ii Purchase an additional sterilizer of the type they currently have at a cost of 417 000 iii Outsource additional sterilization but the cost of outsourcing is 36 higher per disposable syringe than the cost of sterilizing in house Which option and or other ideas would you recommend to MedTech 2 This problem is only for graduate students 8 20 pts Read the following problem description for a foundry and answer the questions concerning it Founding or casting is the process of forming metal objects by pouring molten metal into molds and dates back to before 4000 B C Today casting accounts for about 1 5 of all ferrous production annually and is also used extensively with a variety of nonferrous metals The most common type of casting and the predominant type at ABC is sand casting In sand casting the mold is made by packing sand around a pattern Once the pattern is removed a cavity remains that is filled with molten metal Interior surfaces of castings are formed by placing preformed sand cores into the mold cavity The void between the core and the mold surface formed by the pattern imprint is what eventually becomes the casting Quite complex castings can be created in this way After the metal has solidified the casting is separated from the molding sand and the sand is recycled The casting is then sent to a cleaning station for the removal of any remaining sand scale and excess metal The final quality of a casting depends critically on the proper conditioning of the molding sand Various binders and additives including clay and water are added in a mixer Coarse sand agglomerates are broken up in an aerator so that the particle size is uniform The objective of this conditioning is to have a sand that has adequate strength and plasticity for making and handling the mold maintains sufficient strength when the moisture is driven off by the heat of the molten metal to resist erosion and does not become so hard when heated that it is hard to remove from the casting Up to five pounds of sand is prepared and handled for every pound of metal poured in a foundry Clearly the handling of sand is a large part of operating a foundry A timely supply of properly conditioned sand to the molder s hopper is critical to a foundry s efficient operation Once in the molder s hopper the molder takes sand as necessary to form the molds A schematic diagram of the sand handling system at ABC is shown in Fig 1 3 New sand Cores Additions System storage Sand mixer Aerator Molder s hopper Mold Metal Screening Shakeout Metal castings cleaning Core butts assorted waste Figure 1 Schematic diagram of sand handling process After the sand is separated from the casting this is