1 / 21

IENG 471 - Lecture 06

This lecture covers the importance of facilities planning in relation to cell production rate and production control policies for material flow. It discusses space considerations, production control methods, flow factors, flow intensity, and data collection techniques.

Download Presentation

IENG 471 - Lecture 06

An Image/Link below is provided (as is) to download presentation Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author. Content is provided to you AS IS for your information and personal use only. Download presentation by click this link. While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server. During download, if you can't get a presentation, the file might be deleted by the publisher.

E N D

Presentation Transcript


  1. IENG 471 - Lecture 06 Flow: Quantitatively and Qualitatively Measured IENG 471 Facilities Planning

  2. Depends on cell production rate and on production control policy for material flow Space Considerations • Equipment footprint • Utilities space • Maintenance space • Operating space • (Operator space is discussed AFTER Exam I) • Material space • Tooling space • Scrap space • Work-In-Process (WIP) • Receiving Space • Shipping Space • Plus Material Transportation! IENG 471 Facilities Planning

  3. Production Control of Flow • Push Production: • Traditional • Build To Schedule • Cell Efficiency Effects – Optimal • Overall Efficiency Effects – Sub-Optimal • Pull Production: • JIT (Just In Time production) • Kanban • Production Card (POK) – authorize production of parts • Withdrawal Card (WLK) – authorize delivery of parts • Minimizes WIP (and a host of other problems!) IENG 471 Facilities Planning

  4. Flow Factors • What makes moving a thing difficult? • Size L x W x H • Weight mass per unit • Shape awkward/compact • Fragility delicate / sturdy • Value wood / gold • Condition sticky / hot / wet / frozen • Equipment fork truck / cart / crane • Distance short / long / elevation change IENG 471 Facilities Planning

  5. Flow Intensity • Four Basic Factors of All Moves (Phillips) • Materials • Methods of handling • Moves (distance & elevations) • Money cost of mfg. philosophy cost of materials movement cost of handling equipment IENG 471 Facilities Planning

  6. Flow – Quantitative • Equivalent Load Unit • Accounts for volume and method • Approximates cost (macro-level) • ELUs become the unit of measure for flow between pairs of areas (dept.s) • Flow is tracked on a square matrix • Seek to minimize the sum of the flow volume and distance product for each pair of areas IENG 471 Facilities Planning

  7. From – To Chart • Similar to Map Mileage Charts: • Matrix of Departments (Mfg. Cells) • Cell entries quantify flow AND direction of flow between departments • Steps to Create: • List departments in OPC sequence • From department is listed vertically • To department is listed horizontally • Establish Equivalent Load Unit measure • Distance Qty Cost/Trip* • Record flow volume in chart • Above diagonal is forward flow • Below diagonal is back-track flow IENG 471 Facilities Planning

  8. Data Collection: From – To Chart • Set up a spreadsheet with extra wide / tall cells • Define ELU units between departments • Could be different in each cell! • Use tally marks to track trips • Could scale for high trip counts • Final tally is ELU trips per unit time IENG 471 Facilities Planning

  9. From – To Chart: Flow Qty • Order according to OPC flow • Above diagonal is forward flow: • From Dept. is on Left • To Dept. is on top • ELU volume (number of trips) is entered in the cell • Below diagonal is back flow: • Often rework / scrap IENG 471 Facilities Planning

  10. Flow – Qualitative • Closeness Ratings • Accounts for info transfer & contact frequency and intangibles … • Noise tolerance, control needs, aesthetics, security, dirt control, safety issues, etc. • Rating Scale for closeness: • A – absolutely necessary • E – especially important • I – important • O – ordinary closeness OK • U – unimportant to be close • X – closeness is not desirable • Examples: • Machining Center for magnesium parts and: • First aid station • Raw materials supply for the center • Fire suppression station • Packaging (cardboard) storage • Next workstation on Operations Process Chart if next operation is • Assembly • Inspection • Liquid paint IENG 471 Facilities Planning

  11. Relationship Chart • Qualitative Flow • Obtained from Interviews • List departments • Conduct interviews • Define criteria • Establish relationship value & reason for all pairs • Review chart with ALL involved parties for evaluation & discussion IENG 471 Facilities Planning

  12. Relationship Chart - Example IENG 471 Facilities Planning

  13. Evaluating Flow Information IENG 471 Facilities Planning

  14. Estimating Dept. Space • Space must be allowed for the activities carried out in the departments • Typical Information to capture for Equipment: • Machine Data (manufacturer, type, model, s/n) • Location of safety stops (big red buttons, …) • Floor loading (weight of machine) • Height, width, depth (static – non-operating) • Maximum operating travel (up, left, right, back, fwd) • Maintenance space and location (remove & repair) • Plant service spaces and locations (utilities) IENG 471 Facilities Planning

  15. Estimating Dept. Space • Space must be allowed for the activities carried out in the departments • Typical Information to capture for Materials: • Receiving and In-bound storage • Work In-Process • Out-bound storage and Shipping • Waste storage and Shipping • Storage for unused tools, fixtures, jigs, … • Storage for maintenance equipment IENG 471 Facilities Planning

  16. Estimating Dept. Space • Space must be allowed for the activities carried out in the departments • Typical Information to capture for Operators: • Operator while working • Operator while resting • Operator while handling material • Operator while entering (ingress) and leaving (egress) • Remember Ergonomic considerations! IENG 471 Facilities Planning

  17. Space – Production Floor • Personnel need space for: • Operating equipment • Dependent on operation • Interview operators, observe similar cells • Material Handling • Dependent on material and sizes • See Tables 3.3 & 3.4 (see next slide) from Bozier, et. al. • Ingress & Egress • Dependent on safety, equipment footprint: • 30 inches between static objects • 36 inches between static object & operating equipment • 42 inches between two operating pieces of equipment IENG 471 Facilities Planning

  18. Estimating Aisle Space • Flow Analysis allows us to estimate space required for the materials going through the departments • Also need to allow for space for moving materials moving between departments • Typically, this is based on the size of the From department (footprint), the size (of load) and the method of movement (equipment size) IENG 471 Facilities Planning

  19. Aisle Space Example • Assume a reaction-injection molding (RIM) cell handling car bumpers: • Cell dimension is 50 ft x 15 ft = 750 ft2 • Bumper size is 6 ft x 1 ft = 6 ft2 • Aisle is desired between two operating cells (lengthwise): • Using Table 3.3: (15%)(750 ft2) = 2.25 ft = 27 inches 50 ft • But, subject to OSHA, use the 42 inch width between operating equipment! IENG 471 Facilities Planning

  20. Aisle Space Example – Cont. • Assume a RIM cell handling car bumpers – and a pallet of bumpers at the end of the cell that is moved by a pallet-jack (manual platform truck) • Using Table 3.4: Aisle width is 5 ft = 60 inches • OSHA Requirement: 42 inches (worst case) – met! • Bumper size is 6 ft x 1 ft: so increase to 6 ft = 72 inches • But, the aisle is blocked while loading pallet, must allow for two-way flow of bumper pallets: so increase to 2 x 6 ft = 144 inches • And then add some space for clearance! IENG 471 Facilities Planning

  21. Questions & Issues • Changes to Schedule: • Interactive HW4 work period 28 SEPT • Bring charged tablet & working HW3 model • Check model & improve operation before submission 03 OCT • Topic Review & HW solutions 03 OCT • Exam I date 05 OCT • See me for alternative examination arrangements • Exam I Solution 9:00 AM 10 OCT IENG 471 Facilities Planning

More Related