PROPOSED EXERCISES

Problem 1.
Mango slice line in 1kg cans.
Selection
The mangoes will be selected by size at the time of unloading to be packaged.
apart. They are then placed in boxes to be transported on a platform cart to the conveyor belt.
of bald.
Bald
The boxes are unloaded onto the peeling conveyor. The peeling is done by hand using peelers.
special or short. This work is carried out by workers at a rate of 60 kg of mango per hour and a
100% compliance.
Cortado
The slices will be cut with special curved knives, in such a way that the thickness of the slice
the extracted part should be as large as possible but without any portion of the seed being incorporated into the slice.
This task will be carried out by workers at a rate of 40kg of mango per hour with an overachievement.
of 0.25%.
Washing
The slices will be rinsed with a low-pressure water shower immediately before proceeding to the
filling, to remove shell particles, etc. The mat must have a turning bump for
wash the slice all over with slightly acidulated water.
Manual filling
First, the slices are filled by hand using gloves and placing them evenly.
distributed in the packaging. It should be noted that slices of different sizes will be filled
in separate containers. An operator can fill 2.5 kg of slices per minute.
Next, a boiling syrup with citric acid will be added. This task is carried out
with a manually operated syrup dispenser, which can fill 10 cans per minute.
Exhauster
The cans or jars will be passed through an 'exhauster' with a residence time of 10 minutes.
in such a way that the product comes out at a minimum of 85ºC. The exhauster operates at a rate of 20 cans per
minute.
Fenced
Immediately after the cans are filled, they will be sealed to prevent the product from cooling.
The used capper is automatic with adjustable speed to regulate the number of cans to be capped.
per minute. The regulation is 10-60 cans per minute.
Note. No more than 25 minutes should pass from covering to sterilization.
Placement of the baskets
The cans are placed in baskets of 240 cans to be transported by means of a differential.
towards the autoclave.
The placement in the baskets is done manually at a rate of 25 cans per minute (it's almost
simultaneous with the hidden one.
Transport by means of the differential
It is done in one minute in which two baskets are filled.
Sterilized
An autoclave with a capacity of 3 baskets is used and it lasts 15 minutes when sterilizing.
1kg cans.
Cooling
Next, cooling is done to 40-50ºC in the autoclave itself. This cooling
It takes 15 minutes for the 1kg cans.
Finally, the cans will be labeled, packed, and stored according to their respective standards.

Product details
The mango for slices has a weight yield of 40%.
The content of a 1kg net weight can is given by the following formula: 70% slices
but 30% syrup.
Note: Data on peeling and chopping mats.
These mats have a width of 80cm and their length should not exceed 10m.
Each worker needs 70cm to work in front of the mat. Each mat should be given a margin.
40cm at the ends. At the entrance and in the discharge, the separation between mats must be
2m.
The workers are positioned on both sides of the mat.
With this information:
a) Build the flowchart of the process indicating the inputs and outputs of materials.
b) Identify the limiting equipment of the production line. The equipment includes: exhauster, capping machines and
autoclave.
c) Adjust the line to the limiting equipment.

Problem 2.
Production flow, canned tomato line in 1kg containers.
The tomatoes are transported to the establishment in boxes that contain 20kg of products.
Selection
The tomatoes are unloaded onto the mat where those vegetables will be manually separated.
inept for the process. On average, 20% of vegetables are removed in this activity.
The standard per worker is 50kg/h with a 110% compliance.
Bald
From the selection mat, the tomatoes will move to the burners that will provide an even roast of
the entire skin without penetrating the mass of the tomatoes.
Next, the peeling will be completed, removing the skin and cleaning the tomatoes.
of rotary washers with pressure water shower.
Burner capacity: 100kg/tomato/hour.
Capacity of the peelers: 100kg/tomato/hour.
Heartbroken
Next, they pass through the heart-breaking mat where workers equipped with gloves and
special knives remove the heart and part of the seeds, taking care not to damage the dough
from the vegetable. In this operation, a 10% weight loss occurs from the vegetable.
Standard per worker: 40kg of clean tomatoes/h. 100% compliance.
Rinsing, sorting, and packaging
Next, the tomatoes are transported via conveyors to tables with containers.
both sides equipped with pressurized water faucets, where the tomatoes will be washed manually
with water, for the tomatoes any leftover seeds.
Standard per worker: 40kg clean tomatoes/hour. 100% compliance.
After being rinsed, they will be sorted according to their color and size and placed in
different containers according to their quality.
On average, 5% of the tomatoes that arrive at this activity are diverted to others.
processes for not having the required characteristics.
Standard per packaging operator: 2kg of cleaned tomatoes/min.
Standard per operator classification: 30kg of clean tomatoes/hour.

Exhauster
After the containers are filled, they will go through an exhauster that works at a rate of 20 cans/min.
Covered
The containers will be immediately sealed and placed in storage at a rate of 10-40 containers/min.
They will be taken to the sterilizer within a maximum of 15 minutes after being sealed.
The containers placed in 80-container batches are taken to the autoclave.
Sterilized
It is carried out in 4 autoclaves, each with a capacity of 2 containers, which must remain
15 minutes.
Cooling
It is then subjected to cooling in the same autoclave, which takes 15 minutes. Finally, the
The product is labeled, packed, and stored according to standards.

Product data
1kg container: 50% tomato, 50% vinegar and spices.
With this information:
a) Build the flowchart
b) Adjust the line to the limiting equipment
c) Determine the number of autoclaves needed
d) Labor requirement for manual operations.
Problem 3.
Quilt manufacturing
The company Happy Dreams is dedicated to the manufacture of home textiles, specifically to
quilted bedding. The manufacturing process begins once the
raw materials needed to launch the manufacturing orders for customer orders.
If the raw material needed for the production of an order is not at the table top.
cut, you need to go to the warehouse to obtain the raw material (napa, lining, and upper fabric).
The duvet is made up of three parts: the top fabric, filling (batting), and the lining, which are placed in
the quilting machine on a wooden frame or structure equipped with some punches whose
the mission is to hold the three pieces. Once the three pieces are fixed, the sewing is automatic,
following the design instructions of the chosen drawing.
Once the three necessary pieces of fabric are cut, they are taken to an auxiliary table that is
find at the machine's base, and are fixed to the frame (wooden frame). Placed the frame in the
the machine proceeds to automatic sewing. The quilting machine can only perform a
duvet every time.
After the automatic sewing is completed, the frame is removed from the machine and placed on the auxiliary table.
where the frame is disassembled and the duvet is taken to the thread cleaning table.
Once cleaned of threads, they are packaged and stored until shipment.
The plant layout of the company is as follows:

M4 Table
Auxiliary

M3 Table
Auxiliary

M2 Table
Auxiliary

Table of
Cut of
M1 Table Threads
Assistant

Table of
Cut

Raw Materials Warehouse Finished Product Warehouse

Detailed description of the stages
Cut of napa
The nap (polyester fiber) supplied in rolls of approximately 30x2.60m is cut into pieces.
approximately 1.60x2.60m which corresponds to what will subsequently be the width and length
of the comforter.
The process of cutting napa consists of.
Take and prepare the napa roll on the cutting table (remove the protective plastic cover and
bring the roll closer to the table.
To measure.
Cut manually.
Fold and stack.
Throw the cuttings into a bin.
Cutting of the lining and outer fabric
The fabric that will form the top layer of the duvet is supplied in 100m pieces and needs to be cut.
in pieces of approximately 1.60m.
The process of cutting the lining and upper fabric consists of:
Take and prepare the roll on the cutting table.
Measure.
Cut manually.
Stack.
Assemble the frame
Once the three fabrics are cut, they are fixed to the auxiliary table of the quilting machine.
machine frame. They are placed in the following order: top fabric, batting, and lining fabric.
Change the frame
When the machine has just finished quilting, the frame is removed from the machine and placed on the table.
assistant where the quilt is unhooked from the padded frame.
At this stage, it is used to replace the tap every certain number of cycles to prevent that the
this thread runs out halfway through the mulching operation.
Thread cutting
This operation consists of the cleaning that is carried out on the quilt once it is padded. Cleaning
regarding the threads that remain unstitched between two points of the stitching forming bastes that exist
what to remove.

Prepare bales
After cleaning the excess threads from the comforters, they are packed for transport to
warehouse, in the form of bales wrapping them with a protective cloth to which they are tied at the
points.
Machine quilting
During this operation, the worker does not intervene except to alleviate any contingency.
like thread breakage, breakdown, etc.
The sewing time will depend on the duration of the design being worked on.
the concept of drawing duration is related to the complexity in terms of development due to
its design, of that drawing, so the study will have to be conducted based on the existence of
variable times due to having different models of items.
Build the process operation diagram and the flow diagram.
Problem 4.
Production of chairs model: IND-2013
The manufacturing process of a chair is composed of the manufacturing processes of each one.
of its parts, that is to say of:
Back legs
Front legs
Base plates for the seat
Footrest
Seat
Backup
Manufacturing process of the rear legs
Take a wooden board and cut it to a certain size on the bandsaw, falling to the ground the
scrap wood.
Deposit the cut board to a certain size on top of a pallet (wooden deposit)
cut.
Take the board (cut to a certain size) from on top of the pallet and place it on top of a
table and mark it to the size of a template close to the back leg.
Take the board marked with the template to a pallet (marked wooden deposit).
Take the marked board and take it to the band saw to cut it where it is marked.
falling to the ground the remaining wood and leaving the piece close to the back leg.
The piece is taken to the molder to cut it to the exact thickness of the back leg.
The piece with the exact thickness is taken to the trimmer to be cut to the exact width.
from the hind leg, the obtained piece is already a hind leg.
The hind leg is taken to the multiple drill and holes are made in it, where more
Go ahead, in the assembly position, the footpeg spigots will be inserted.
joints that serve as a base for the seat and the backs.
The leg with the drilled holes is taken to the flat piece sander (there is a deposit of
pieces before and after the sander.
The sanded leg is taken to the edge sander to round off the edges.
Finally, the leg is taken to the assembly station to fit it with the other pieces.
Manufacturing process of the front legs
Take the wooden plank and cut it to a certain size on the bandsaw, falling to the ground the
surplus wood.
Deposit the cut board to a certain size on top of a pallet (wooden deposit)
cut.
Take the board (cut to a certain size) from on top of the pallet and place it on a.
table and mark it to the size of a template roughly to the front leg.
Take the marked board with the template to a pallet (marked wooden deposit).
 Take the marked board and bring it to the bandsaw to cut it where it is marked.
falling to the ground, the remaining wood and leaving the piece close to the front leg.
The piece is taken to the molder to be cut to the exact thickness of the front leg.
The piece with the exact thickness is taken to the template cutter to cut it to the exact width.
from the front leg, being already the obtained piece a front leg.
The front leg is taken to the multiple drilling machine and holes are made in it.
forward in the assembly position, the footrest spikes will be inserted and of the
joints that serve as the base for the seat.
The front leg with the drilled holes is taken to the flat parts sander (there is
deposit of parts before and after the sander.
The sanded leg is taken to the edge sander to round the edges.
Finally, the leg is taken to the assembly station to fit it with the other parts.
Manufacturing process of footrests and joints for seat base
The joints and footrests are physically identical pieces, although their function is different, that's why
the manufacturing process is the same:
Take the wooden board and cut it to a certain measurement on the band saw, falling to the ground the
excess wood.
Deposit the cut board to a certain size on a pallet (wooden deposit)
cut off).
Take the board (cut to a certain size) from the top of the pallet, place it on top of a
table and mark it to the size of a template approximately to the joint or footrest.
Take the marked board with the template to a pallet (marked wooden deposit).
Take the marked board and bring it to the band saw to cut it where it is marked.
Falling to the ground the remaining wood and leaving the piece close to the joint or footrest.
The piece is taken to the molder to be cut to the exact thickness of the joint or footrest.
The piece with the exact thickness is taken to the template machine to be cut to the exact width.
from the joint or footrest, with the piece already obtained being a joint or footrest.

The piece is taken to the flat piece sander (there is a storage for pieces before and after)
the sander).
The sanded piece is taken to the edge sander to round the edges.
The board or footrest is taken to the reaper and the spigots are made for it later.
they will be inserted into the holes of the legs at the assembly station.
Finally, the footrest or footpeg is taken to the assembly position where it is fitted.
spigots of the joints with the middle holes of the hind legs and the holes
upper parts of the front legs and the spigots of the footrests with the holes
lower parts of the hind and front legs.
Manufacturing process of the seats
The seats are bought already cut:
The purchased seats are already cut, their edges and corners are sanded on the general sander.
The bolt (there is a parts deposit before and after the sander).
 The sanded seats are taken to the assembly station where they are glued to the joints that serve.
based on the same.
Manufacturing process of the backs
The purchased backs already finished (without paint and lacquer) are taken to the assembly station where they
the spigots of the backs fit into the upper holes of the rear legs (the
backings are already purchased.
Manufacturing process of chairs
Once all the pieces of the chair (back legs, front legs, footrest, joints of
base for the seat, seat and backrest) in the assembly station, they fit together in a way
manual (there is a parts deposit before assembly).
Then the fitted chair is taken to the hydraulic press and the joints are tightened.
The chair is left in the warehouse to be lacquered and painted.

It is then taken to the lacquering and painting booth and is lacquered or painted.

The finished chair is taken to the finished product warehouse.

Then it is taken to the packager to package the chairs.
Finally, it is left in the packaged product warehouse.
With this information:
1. Build the Operations Diagram, Flow Diagram, and Path Diagram of
manufacturing process of the chair model: IND-2013.
2. Analyzing the graphs, what proposals would you make?
Additional data:
Laca: crystal 322.
Shrink wrap plastic 009
Glue: 02567 superglue
Oak wood 1825
Backup model: [Link]-2013
Seat model: [Link]-2013
Generally, the company works in batches of 50 units, so until it is completed
the complete batch does not move to the next stage. The intermediate deposits act as warehouses
intermediaries of the batches of parts.