Manufacturing Process Exercises DAP
Manufacturing Process Exercises DAP
DAP OPERATOR/MATERIAL/EQUIPMENT
Diagram No. 1 Sheet No. 1 SUMMARY
ACTIVITY ACTUAL PROPOSAL ECONOMY
OBJECT: Corrugated pipe for sewer
Operation
Manufacturing Process Method: Transport
Actual Wait
Place: The whole plant Inspection
Storage
Worker
Distance metros
Time minutes
Cost
Composed of: Date:
Labor
Approved by: Date:
Material
TOTAL
Symbol
Description Can't. Dist. Time Observations
⃝ → D □
Transported by provider
INSPECTION
STORAGE
Transported to cutter
WAIT
CORTADO
Transported to Trainer
Take Body
Transported to Drill
Drilling and Riveting
STORAGE
Transported to Station of
Embark
2.B.B.S.A. is a company dedicated to the manufacture of baby products.
from its items is a towel set "little bear", which consists of the following
pieces: a plush towel with bias trim; and a mitten with
application, also edged with bias; and a plush trim, edged
also.
It is requested to prepare the DAP, if the production process being followed is the
next
A roll of the plush is taken from the raw materials warehouse and taken to the workshop.
sewing. In this workshop, a roll of 1.50 meters is placed on a table.
widths and the fabric is laid out with a length of 0.88 meters
(approximately 45 lays are made).
Once the fabric is laid out, the templates of the pieces to be cut are pinned down.
to be used in the making of the towel; then proceeding to outline its contours
with a pen.
Then proceed to cut with an electric round blade cutter.
removable. From the formed scraps, the applications are marked with a pencil.
they are used, they are cut and then placed in a basket to take them to the
seamstresses (zone 1).
The workers are sewing the application to the hood with zigzag stitches.
glove. When they are ready, she places them in a basket. The basket is moved to
another sewing machine (area 2), where other workers are then carrying out the
edging operation, placing the bias along the entire edge of the towel with
his hood, to the drool and to the mitten.
Once these operations are completed, the pieces are moved to a table where
a review of the seams made, to then send them to the ironing area.
After ironing the pieces, they are transferred to another worker, who
in charge of folding the towel into a rectangle of approximately 10 x 15
inches; another worker takes the ones that are ready together with the other pieces and the
put it inside a bag. Then proceed to put the label (printed paper
that details the product features) to finally close it and be transferred
to put it on a display case, to then transfer it to the product warehouse
finished.
DAP OPERATOR/MATERIAL/EQUIPMENT
Diagram No. 1 Sheet No. 1 SUMMARY
ACTIVITY ACTUAL PROPOSAL ECONOMY
OBJECT: Corrugated pipe for drainage
Operation
Manufacturing Process Method: Transport
Actual Wait
Location: The entire floor Inspection
Storage
Operator: Card No:
Distance subways
Time minutes
Cost
Composed of: Date:
Labor
Approved by: Date:
Material
TOTAL
Symbol
Description Can't. Dist. Time Observations
⃝ → D □
Transport to the sewing workshop
Spreading of the fabric
Outline with Mold
Transport the Cutter
Cut and shape
Transport the Seamstress 1
to cook
Transport the Seamstress 2
Place the Pieces
Transfer to the table
Review of Completed Seams
Transport to Ironing
Iron the Pieces
Transport the Operator
Fold Towels
Bagged
Labeling
Sealed
Transport to Sideboard
Storage
EXERCISES ON PRODUCTIVITY
Exercise number 1:
An agro-industrial company wants to determine the productivity of a new
article that will be launched on the market, in 450 gram polyethylene bags. The material
The daily required raw material goes through three basic processes:
X
A 75 Kg B 30.360
33.5% C 29725
18% 1%
16.46 0.91
91.46 ------------ 100 % 75 ---------- 82%
X ---------------- 18% X ----------- 100%
X = 16.46 91.46 kg
i) 29725
0.07 x 30 = 2.1
1.5 x 9146 = 137.19
0.15 x 66 = 9.9
Machinery:
0.085 x 75 = 6.375
0.03 x 66 = 1.98
= 8.3357
Raw Material: 0
66
vi) P = 0.29 bags/unit
274.4875
Exercise number 2:
In a company, 500 kg of fruits were used as raw material and 350 were obtained.
kg of pulp. Find the efficiency of the raw material.
SOLUTION:
MP Efficiency =3500.7
500
Exercise number 3
Solution:
X -------------- 100%
50 kg
X = 71.4 Kg
X --------------- 63 %
50 Kg
45 Kg
1500
iii) Productivity =7%
21420
DIRECTED PRACTICE OF METHODS I
Solution:
X - 0.01x = 0.9x
0.9x - 0.18x = 0.72x
462.96 Kg
300
i) Efficiency MP = 0.648
462.96
X cans 462960
X = 1543 cans
SOLUTION:
3. The following presents the process and method for performing a task in a
plastic products plant: PROCESS: this plant works with resins
thermoplastic synthetics, Injection Molding or 'casting to
pressure. It is a method in which the melted plastic in the cylinder of the
injection machine is required to pass in a fluid state into a mold. It is fed
the machine's hopper with polystyrene then the machine's cylinder melts the
plastic (operation called 'plasticization' that is performed only by the
machine), plastic is injected into the mold, the mold opens, the product falls out, it
The worker collects the product and places it in a storage. METHOD: the method
the next step for the worker is: Take a bag with plastic, throw the plastic into
the hopper, opens the machine door to collect the product (cup) and leaves the
product in a box. It is requested to subdivide the task (producing mugs) into elements.
Raw Material
Put in a deposit
FINISHED PRODUCT
4. 1880 h00write it in: seconds, minutes, hours, hundredth of a minute.
Consider 2 decimals and 1 minute = 166.6666 hours
Centenary
Data Segundos hours of the minute
1880 h^00 676.80 11.28 0.188 1128
SOLUTION:
L = Load + Unload
m = Machining
+
N=
N =5 + 20= 5
5
Cycle:
A factory has four machines and four operators. In another area of the
factory, urgently requires two workers, given this situation, it is desired
to know
Cycle:
3. There are three machines: brush, milling machine, drill; which perform a work
sequential, whose processing times (in min) are:
SOLUTION:
C = 25 min/each
10
11
12
13 DYCM2
14
15
16
17 It's going to M3
18
19
20
DYCM3
21
22
23
24 It goes to M1
25
26
27
28
29
DYCM1
30
31
32
33
34 He/She is going to M2
35
36
37
38 DYCM2
39
40
41
42 He/She is going to M3
43
44
45
DYCM3 C = 25 min/each
46
47
48
49 He/She is going to M1
50
51
52
53
54
DYCM1
55
56
57
58
59 It goes to M2
60
4. There are three machines: lathe, drill, press. Each machine produces a
different article: axes, speakers, caps. A production is desired.
minimum of 30 units/day (of each item). It is known:
SOLUTION:
C = 41 min/und
11 units of each item are produced per day with 1 worker for the 3.
machines.
SOLUTION:
B) C = 32 min/ und
SOLUTION:
Random service
1. In a company, statistical sampling has been conducted and it was found that for the
Generally, machines work 75% of the time.
a. Determine how many machines should be assigned to an operator. Carry out the
verifications for 3 and 4 machines.
b. Determine the daily production, if the cycle time is 10 min/unit.
SOLUTION:
–
N= =
N =
4 = 10 / TO TThe= 2.5
480 h/day
P= = 48 and/day
10 min/unit
2. The normal production of a company (installed capacity) is 150 units/hour.
it is determined that the four machines (due to their age) only operate at 70%
of the times. If the machines are attended by an operator, determine.
Solution:
p = 0.7
q = 0.3
0 0.2401 0
1 0.4116 0*
2 0.2646 (1)(0.2646)(8)
3 0.0756 (2)(0.0756)(8)
4 0.0270 0.648
1.00 3.97 H
(0.2401)(8h)
X 100 = 24% worker
(8h/paper)(1paper/region)
3.97 H
X 100 = 12% machine
(8h/m²)(4 m²)
8h - 3.97h
c) Efficiency = = 20%
4 maq x 0.05 h/unit
3. The company AZ Service has 12 identical machines, attended by 3 operators. It
a worker with the same skill is required for another section, therefore there exists
the possibility of reallocating one of the workers, or alternatively, hiring a new one
worker.
For this purpose, 120 observations have been made on the set of machines.
finding that a machine did not function 36 times.
4. When conducting a methods analysis, it was observed that the machines, on average
they operated 40% of the time without requiring attention and the average or probability
that are not functioning and require the operator's attention is 60%, you
decide to make the comparison by assigning the operator who handles several drills
automatic, the possibility that it works with only 3 or 4 machines.
SOLUTION:
Sorting we have
8.64 h/máq
= 27 %
32 h/máq
They intervene in the process: an expert worker in the handling of the pneumatic hammer,
a plumber, a worker who uses a pick and a shovel, two assistants A and B and a
starter.
The process is as follows:
The assistants take down all the necessary tools and materials from
truck (5 min).
Assistant A marks the area to be drilled (8 min).
Assistant B brings the pneumatic hammer together with the hammer operator.
(3 min).
The drill pierces the marked area (10 min).
The other worker instructs the helpers to remove the pieces to the side,
and supervises them (8 min).
With skill, this worker drills a hole, alternately removing the
earth with the shovel (5 min).
The plumber connects the pipe and asks assistant A to place it together.
water intake (12 min)
Then, assistant B covers everything with the excavated soil and compacts it.
firm (10 min).
While he works, the cement worker prepares the mixture, which is then
will be allocated to the finishing of the sidewalk (5 min).
Finally, the helpers pack up all the tools and leftovers from the
truck (5 min).
Although the driver does not intervene in the process, it is important to highlight that throughout this
time, was reading the newspaper.
Ground Coffee
3. Wrap Toys
Analyze the activities of these four workers (there are activities that have not been)
mentioned), using the crew diagram. Indicate the performance of each
worker. (The package of 3 boxes is considered as one processed unit).
SOLUTION:
Cycle:
4. Tracheotomy
After the diagnosis, the 'primary physician' performs their next activity and then
At the same time, the 'nurse' informs the 'supervising nurse' to open the
operating room.
Subsequently, the 'nurse' informs the 'second doctor' to carry out his
first activity.
Immediately after, the 'nurse' informs the 'nurse' so that both
take the patient to the operating room and at the same time the "assistant" performs their first
activity.
On the other hand, the 'first doctor' performs activities 3, 4, and 5 in a manner
sequential. However, he cannot perform the tracheotomy until the
Second doctor, operate and place the endotracheal tube.
The added value can be derived from the operations that take place in the area.
from the packaging machine.
3. Determine the combined cost index, based on the information contained
in the following process diagram:
SOLUTION:
Solution:
The study of times proper.
6. Indicate the two conditions that must be met before conducting a study.
of times.
Solution:
Having the right materials for the case
I have conducted a respective methods study.
EXERCISES ON EFFICIENCY AND PRODUCTIVITY
Solution:
Expenses:
90000 sheets x $30 / thousand = 2700
80 diplomat sheets x $3 = $240
Diplomat copy 80 sheets x $1 = 80
Printing 90000 x 0.02 = 1800
9. The Líber bottling company produces papaya juice. The processing of a batch
"Paila" produces 2.472 bottles of juice. The components of a paila are 350.
50 Kg of water and 5 Kg of other ingredients (citric acid,
coloring agents, ascorbic acid, sodium benzoate, essence, pure water) the price of
30 soles
Soles. The process that includes: peeling, cutting, packing costs 16,500 soles.
the pan. Additionally, it is known that peeling the papaya results in a 40% waste and the
extract discards 6.57% of the weight of papaya used - Each bottle is sold
at 29 soles, it is requested to determine:
Enter:
350 Kg x 0.40 = 140 Kg
350–140 = 210 Kg
Sale:
210 Kg x 0.0657 = 13.797 Kg
210 Kg - 13.797 Kg = 196.2 Kg
Ef =196.2= 0.56
350
a) Physical efficiency
b) Economic efficiency
Solution:
Ingresos: 157937.5
500 x 35 = 17500
Ee=157937.5= 9.02
17500
TURKEY PROCESSING
A worker A goes to the live turkey depot and collects 6 using a pole.
aluminum with rope. Then the same worker takes them to the block for the
head cutting, where an operator B picks up the turkeys one by one to
place them in the funnels and kill them, where they drain the blood. The function of a
worker C is to pick up the 6 dead turkeys and take them to the tub
hot water and boil them; then, he takes them himself to the plucking, where
a worker D and his 2 assistants pluck the birds. Then, one of the
helpers take the 6 birds to a plastic storage, where an operator E
choose the turkeys, checking that there are no feathers remaining, removing them if there are
Another worker F picks up the 6 turkeys, flames them one by one and then
take everyone together to the cleaning table. At the table, an operator G and his
helpers eviscerate and wash the turkeys, placing the clean and washed entrails
in bags that are inserted into the birds. Immediately a worker H collects
the 6 turkeys and places them in a storage, weighs them one by one, sticking them
sticker with the weighing data. An assistant X, from the wrapping area, collects
the 6 turkeys and takes them to his workplace, where he finds another one.
assistant Z and his supervisor. Once the task of wrapping the 6 turkeys was completed, the
To bring turkeys to
Worker H
Take turkeys to the tub
Gather turkeys
Choosing turkeys
Wrap 6 turkeys
Operator F
Take to frozen