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MidSU08Sol - IE 327 MIDTERM(Sp08 Alt NAME K(3V There are 5...

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Unformatted text preview: IE 327 - MIDTERM (Sp08 Alt) NAME K (3V There are 5 problems on 5 pages worth 100 points. The last pages contains formulas, which you may tear off. Closed book/notes. Show work for partial credit. Clearly state any assumptions you make. Place the final answer in the space provided. I have neither given nor received aid on this exam. (signed and dated) 1) (11 pts) The following activities and times (minutes) for a mold operator were observed by an IE intern: EVENT SYMBOL DESCRIPTION a) removes molded piece from die . b) walks 10 ft. to a bench, boxes piece and puts on pallet 61] c) returns to injection molder h) wfl' . - d) blows out dirt from die (with cempressed air) (3") e) sprays oil into die @ t) presses START button to activate molder and sits dawn d g) molding machines closes die, injects polyethylene 6 into die and after set curing time opens die ) h) cycle repeats itself I a) (9) Complete the following flow process c _ for the op tor . a b) (2) What is the name ofthis chart? . and W 05159 2) (23 pts) a) (5) The following noise exposures were recorded for J. Smith at ABBA, Inc. over his 8-hr work day: 1.5 hours in the press area at 95 dBA 3 hours in machining at 90 dBA 0.5 heur lunch at 60 dBA 1h0uringrindingat92dbA D3 2+2}. -= [fir-3e if: :- “bi’ '2’! ,___ 2 hours in assembly at 90 dBA l ‘ i 1 L" 5 G (3 . Is this exposure acceptable according to OSHA? What is the dose exposure? I I I (190$ (£49130 SOULJD Lei—Wt. HEW—2 b) (2) As an IE, how would yoa measurei’document this? c) (3) What is the resultant time—weighted average noise for the 8-hr day? “ new —; {Mmhflllécmo : Cm ‘i/r/ d) (4) What is the likely result if J. Smith is continually exposed to such noise levels? Be specific about the physiological changes in the ear. (W‘s 6 cos; .9 VFW Dwa- op W2 (52¢; i We e) (4) How would you document this? Be Specific. fl UDHDMWCJ flgnbb/ ‘36 (115% . t) (5) The press area has 5 identical machines. ABBA is considering either adding or removing presses so as not to exceed the acceptable noise dose exposure for J. Smith. What is the resulting number of machines in the press area to accomplish this? 9‘: l 3 5g 15qu ’15}:qu X2 illita‘z it? $879, :9 L%°;.:s5 L: 9033 l: X F‘“ _ s " . . g. . 5’ F lots . .. 0’9!” cross melodioimo q a '31:)Kl l 95935 ;l€OaK+ 8‘13 #machines 2 A 3) (34 pts) The worker shown below is assembling a step stool using the following procedures: _ i) twists to her right to pick up a metal plate fmm a bin on the floor with her right hand i . i ii) sets the plate on the table in front of her and holds it in her left hand ti 1. - I iii) reaches for an angle bracket with her right hand aligns it with a predrilled hole in the plate iv) while the left hand hold the bracket the right hand reaches for a boltm “J v) inserts bolt into bracket and hole in plate E {:{LMM K g vi) right hand picks up pewer nutrunner and fastens boltt'bracket to plate I vii) she repeats steps iii)— vi) two more times (i. e there three legs to stool, all the time holding the plate with her left hand viii) twists to set the plate in a bin on the floor to her left I fir-Rm? i =2 . . a) (10) Assuming her quota is 2 stools per minute, fill out the C‘ TD Risk Indegfiiltgm. K... and W 5070 5251M thew (mom mite-WM? sol/we. b) (24) How would you improve the method to increase productivity? Include specific work design and human factors considerations and give supporting principles or reasons why this design should be effective. Be thorough. Diagrams may be useful. Work Desigr_1 and Methods Change Supporting Principle [Why effective ‘21 I) first. on: ROM-use wWWUK , "WW3 ”“3”“ ‘9) 'EOLTS “.4 BRA‘C'lLt-TK 31L 599”” M” coil/OT WOUND (-1.30%- _~-_ “c - 1 saw 119cm Alt/0&9 Mlflfipmabfl 3} SPT twat: 70 Raawflfsr ember 1 ‘ . . € ) use mum 77201, fit/0H9 {.r’ULNHflDfl/Wflort q “ l C ')Q flQiCéé'n r/CIVO (D m/IG‘GCR {63L6r2 ' “ 30 5-1. out: 6) Ugbfit'cu :9/172 “,2" ABSOKQ ffitficc maul? ) e u a , r :1 Eric) uFfl/Q WJRRPrc‘Ce atmfl sup/Ma q) 8172 {5mm 5mm, ih/Oco Ream/Kr [62.3 {Wiser Ac tea/WWW {0) My: SUSNU Scflrt-LWWILH W 4) (25 pts) One of the Operations in poultry processing involves removing [filb chickens, hanging by t eet, from an overhead conveyor, placing them on a workstation, cutting off the head and legs and placing it on a roller conveyor for further processing down the line. The work is both repetitive and fatiguing; it is not unusual to find heart rates increasing from a resting value of 70 beatsfmin to a high value of 120 beatsfrnin and the Operator complaining of stress levels of 12 on the Borg scale. Evaluate the current situation in terms of manual work and lifting stress. Then redesign the joblworkstation to reduce the stress to acceptable levels. . a r a, All?“ was ; flarfli xiv-v :- 02370 HEY-Hit (2M1 W W i) (so ) TDOW‘éH Mm g Warwnw or; :1 ebno {cubicle ”mommi, 6009 \L . . (a _ KWLofl. ‘4 S‘! C 1-9 >6: l‘iOO reg-“7L0 eaolXi‘bei—iigfi OBSYQ '1 91 (Mom 'HC'KTLKUGW) a we m -15 2'2 9’ 12 (Wipes, : Cin—E’X (roviilciseoifliih gmysms ("#73 "_.....——- _ , w BAD. s.- §,(,92€>%)('.‘5‘i7)ti’>3)@ ” Rem-abs) \l/H +9 to Run, 2 35gb _, (“lit 5??“ ‘- 766i MED Hoes 30g. Remand 914,13 Wt @153 931%,, Mlqu 5mm. 655 b S) (3" pts) Parts #a-f refer to the following chart showing cumulative frequency (in %) of defects for six different jobs (A, B, C, D, E, F) in a plant. a) (2) Explain in <8 words or less what this graph shows. Rivas 305 wini- WJCIOKIW op DEWT'S ‘ b) (2) What is the name for this graph? . stifle?) Ail/fl W S! g c) (2) What is an alternative name for this graph? 80’20 fig U LE ! ‘ r - ' d) (1) Who originated this type of analysis? (Give full name) l: [L nQ U) 0 PM 671) . . t . e) (+1 extra credit) In what scientific field was it first used? t: COM 0 M [C S CTD Risk Index Job Title: VCR Counter No: _ ycle Time (in minuzes; obtain from videotape) C # CycleIDay = (180 -I_unch—Breaks) _ C cIe Time 1 # Parts I Day (if known) # Handmotions I Cycle # Handmotions I Day ((33 x GD) Frequency Factor (Divide @ by 10,000) = 'U Q. 3 H- U} {CIrcIe appropriate condition) n——_ ——(em-—_ ——@ —_ Yes —_ —m'- Yes —_ —c_ Yes _— —[__— ——W—— —ED- Yes —— Yes —— _Y Yes —— —n_sE-—— m-—_ —mm—— ———[email protected]_ sseuussresess reb-——— —_—— Total the Points for the Circled Conditions 5- Posture Factor (Divide (B) by 10) = {- Grip or Pinch Force Used on Task [email protected]®fiby®: Max Grip or Pinch Force 1 5L) Force Factor (Divide® by .15) = 7/ (We appmp’fa’emmjm”) ‘-—— —n_m_—_ sa-——_ —[email protected]_—_ Tssesrseen —_—— ——M—— Miscellaneous Factor (Divide® by 3) = i CTD Risk Index = .3 x (Frequency + Posture + Force Factors) + .‘I x (MisceIIaneous Factor) CTDRisklndex=.3x( {s‘@ + % + '2 )+.1x( I ...
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