1.1 Discuss the operations, processes and processes of one organisation in the Processindustry of your choice.Required:

1.1 Discuss the operations, processes and processes of one organisation in the Process
industry of your choice.
Required:
1.1.1 Main machinery and technology (5)
1.1.2 Explain with diagrams the process layout (5)
1.1.3 The machine – product matrix of the company (5)
1.1.4 Main material handling equipment (5)
1.1.5 Product storage and warehousing processes (5)
1.1.6 Automation and process control (5)
[30]
QUESTION 2
2.1 In a production process run 100 units are produced per 8 hour shift. Set up time is 30
minutes and material-handling time is approximately 40 minutes over the total shift.
Assuming it is batch process:
2.1.1 Calculate Cycle time (2)
2.1.2 The production rate. (2)
2.1.3 If it is batch production calculate time per batch (2)
2.1.4 If the factory has 4 machines operating for 8 hours per day 5 days and 48 weeks per
year. Calculate the plant capacity. Production rate of each machine 6 units per hour. (2)
[8]
QUESTION 3
3.1 For example, at XYZ manufacturers, which manufactures carts, the variable expenses per
cart
Fixed Costs Variable Costs
General Labour R150000 Steel R500
Rent R30000 Direct labour R50000
Insurance R2000 Water R1000
Advertising R50000 Materials R40000
Fixed Utilities R45000
12
(6) If one cart is sold at R2500. What is the break even point.
3.2 Explain the importance of machine availability in achieving production target. How is it
calculated? (3)
3.3 Derive the formula for calculating machine hourly rate. (8) [20]
QUESTION 4
4.1 Explain typical assembly operations performed on a manual assembly line (3)
4.2 Explain the line balancing problem in assembly lines. Explain how element times are
compiled for an assembly operation. (3)
4.3 Assembly a product XYZ has 12 elements whose element times are given below.The
product is assembled manually with annual demand being 150000 units. The line operate
50 weeks pewr year 5 shifts per week and an 8 hour shift. There is one worker pre station
Uptime efficiency is 95% while repositioning time takes 0.08 min.
Element Time for element Preceded by
1 0.3 –
2 0.35 –
3 0.8 1
4 0.2 1,3
5 0.11 2
6 0.6 3
7 0.5 4
8 0.3 6, 7 8
9 0.6 5,8
10 0.5 5,
11 0.13 9, 10
12 0.12 11
Calculate
4.3.1 Total work content and hourly production rate. (4)
4.3.2 Cycle time (4)
4.3.3 Theoretical minimum number of workers (4)
4.3.4 Service time to which the line must be balanced. (4)
[22]
QUESTION 5
Explain the quality programs in manufacturing using practical examples you are familiar with.
Focus on quality management systems, quality engineering, technology in quality control,
statistical tools in quality and development of standard operating procedures and
documentation. (20)