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Chapter 6 – Process Selection and Facility Layout

Chapter 6 – Process Selection and Facility Layout. Process types and selection, automation, layout types, line balancing. Process Selection. Make or buy analysis (See pp.185-186) Q BEP = FC / (p – v) Process types (“type of operations”) Project Job [Batch] Repetitive Continuous flow

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Chapter 6 – Process Selection and Facility Layout

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  1. Chapter 6 – Process Selection and Facility Layout Process types and selection, automation, layout types, line balancing SJSU Bus. 140 - David Bentley

  2. Process Selection • Make or buy analysis (See pp.185-186) • QBEP = FC / (p – v) • Process types (“type of operations”) • Project • Job • [Batch] • Repetitive • Continuous flow • Volume, mix, flexibility considerations SJSU Bus. 140 - David Bentley

  3. Why Automate? SJSU Bus. 140 - David Bentley

  4. Why Automate? • Reduce or eliminate labor cost?? • Apply only to high volume operations?? • Keep up with the other CEOs at the Rotary Club?? • See the ads and say: “Wow, I’ve got to have one of those!”?? SJSU Bus. 140 - David Bentley

  5. Why Automate? • Quality • Assures consistency, low variability • Rapid change • Shortens setups and changeovers • Reduces time to turnaround prototypes • Lower tooling cost • Eliminates specialized tools and dies • Reduced labor cost SJSU Bus. 140 - David Bentley

  6. Automation Concepts - 1 • Product design • CADD – computer aided drawing and drafting • CAD – computer aided design • Process design • CAPP – computer aided process planning • Machine control • NC – numerical control • CNC – computerized numerical control • DNC – direct numerical control • FMS – flexible manufacturing system • CAM – computer aided manufacturing SJSU Bus. 140 - David Bentley

  7. Automation Concepts - 2 • Production scheduling • CAS – computer aided scheduling • Service • CAI – computer aided instruction • Warehousing • AS/RS – automated storage and retrieval systems SJSU Bus. 140 - David Bentley

  8. Automation Concepts - 3 • Robotics • Heavy use in auto industry • Described in terms of number of axes of motion (up to 6) • Arm sweep • Shoulder swivel • Elbow extension • Pitch (wrist) • Yaw (wrist) • Roll (wrist) SJSU Bus. 140 - David Bentley

  9. Automation Concepts – 4 • CIM – computer integrated manufacturing • Integrates all the preceding concepts • MAP – manufacturing automation protocol • Major development in U.S. auto industry SJSU Bus. 140 - David Bentley

  10. Line Balancing Definitions • Line balancing • Balance work among production lines, or • Balance tasks among workstations on 1 line • Cycle time • Materials Management: time from beginning of first operation until completion of last operation, or • Industrial Engineering: time between completion of 2 units of product, or • Line Balancing: Maximum time allowed at each workstation SJSU Bus. 140 - David Bentley

  11. Line Balancing Tools • Cycle time calculation • Output capacity ( OC = OT / CT ) • Where OT = Operating Time per day, CT = Cycle Time • Cycle time ( CT = OT/D ) • Where D = Desired output rate • Precedence diagrams • Similar to network diagram • Measures of effectiveness • Balance delay (% of idle time) • Efficiency SJSU Bus. 140 - David Bentley

  12. Layout Types • Fixed-Position • Process or Functional • Product • Cellular • Mixed SJSU Bus. 140 - David Bentley

  13. Fixed-Position • Product is in a fixed position (e.g., airframe, ship, building, highway, etc.) • Resources (people, machines, material) come to the product • Requires complex scheduling of resources • High space requirements to accommodate resource movement • Usually associated with the Project environment SJSU Bus. 140 - David Bentley

  14. Process or Functional • Groups similar resources together by the function or process performed • Machine examples are: milling machines, lathes, routers, grinders • People examples are: Invoicing, Accounts Payable, Payroll Processing • Many crossed paths, high space requirements • Easy to supervise, train, etc. • Usually associated with the Job and sometimes the Batch environments SJSU Bus. 140 - David Bentley

  15. Product • Resources are arranged to follow the flow of the product • Examples are: auto assembly, steel production, bottling, etc. • Often called production lines or assembly lines • May be straight line, U-shaped, snake • Provides for very little WIP storage • Usually associated with Repetitive and Continuous Flow environments SJSU Bus. 140 - David Bentley

  16. Cellular • Resources (labor and equipment) arranged in small groups (cells) • Have responsibility for output, quality, maintenance, etc. for a grouping of tasks or parts • Referred to as “teams” in services sector • Teamwork essential • May be straight line or U-shaped; no WIP storage • Most recently developed layout • Usually associated with Repetitive environment SJSU Bus. 140 - David Bentley

  17. Mixed • Two or more layout types in 1 facility • Examples • Manufacturing: burn-in or baking • Restaurants (kitchen is functional, buffet line is product, menu ordering is fixed-position) • More difficult to plan • More costly to equip • More troublesome to maintain SJSU Bus. 140 - David Bentley

  18. U-Shaped Advantages • Staff flexibility and balance • Teamwork • Immediate rework • Accessibility • Work and tool distribution • Linking with other U-shaped layouts SJSU Bus. 140 - David Bentley

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