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Supporting Slides

X. Supporting Slides. Systems for Planning & Control in Manufacturing: Systems and Management for Competitive Manufacture. Professor David K Harrison Glasgow Caledonian University Dr David J Petty The University of Manchester Institute of Science and Technology. ISBN 0 7506 49771. 0000.

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Supporting Slides

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  1. X Supporting Slides Systems for Planning & Control in Manufacturing: Systems and Management for Competitive Manufacture Professor David K Harrison Glasgow Caledonian University Dr David J Petty The University of Manchester Institute of Science and Technology ISBN 0 7506 49771 0000

  2. 01 Manufacturing Systems • Objectives • To Understand the Concept of a Manufacturing System • To Understand the Different Types of Manufacturing Systems • To Appreciate the Importance of Manufacturing Strategy • Overview • Manufacturing and the Enterprise • Classification of Manufacturing Organisations • Design of Manufacturing Systems 0101

  3. Economic Role of Manufacturing 01 Agriculture and Construction 0102

  4. 01 Definitions • Material Removal • Material Forming • Casting/Sintering • Chemical/Mixing • Painting • Assembly Process. A means of transforming material from one form into another System. A number of entities acting together as a whole Manufacturing System. A series of value adding manufacturing processes to convert raw materials into more useful forms and eventually finished product. 0103

  5. Very High 01 History Craft Mechanisation Soft Eng. Power Low High Reduced Technology Simple Complex Modular Organisation Small Large Hierarchical Low High Formalisation 0104

  6. 01 The Manufacturing System Process Warehouse Process Queue Process Queue Warehouse Process Queue Process Finished Product Raw Materials Warehouse Process Process Warehouse Process Queue 0105

  7. 01 The Manufacturing Organisation Sales Purchasing Accounts Production Design & Product Planning & Control Development Quality Production Engineering Process Queue Process Process Warehouse Queue Warehouse Process Queue Process Supplier Customer Process Warehouse Base Base Raw Finished Process Warehouse Product Materials Process Queue 0106

  8. Corporate Planning Aggregate Planning Master Planning Intermediate Planning Low Level Planning Process Control 01 Scope of Manufacturing Management 10 Years Decisions: Low Frequency Strategic High Significance 1 Year Tactical 1 Month Operational Decisions: High Frequency Low Significance 1 Day Physical 0107

  9. 01 Classification and Characteristics • Small • Medium • Large • Chemical • Metal working • Electronic • MTS • MTO • CTO • ETO • Fixed Position • Process • Product • Cellular • CNC • FMS • Manual • Job • Batch • Mass • Process Variety "D" Finished Goods “P" • Size • Type of Product • Market • Machine Layout • Technology • Material Flow Components Or Sub-Assemblies Raw Materials High High Complexity Control Product Complexity Low Low Job Batch Mass 0108

  10. 01 Stock and Manufacturing Systems - 1 Make Buffer Process Buffer Process Buffer Process Warehouse to Stock Configure Buffer Process Warehouse Buffer Process Buffer Process to Order Make Warehouse Buffer Process Buffer Process Buffer Process to Order • It is Desirable to Commit Material as Late as Possible • Holding Material at a Low Level will Minimise Stockholding 0109

  11. 01 Strategy What is the Purpose of the Organisation? Statement of Aims Mission Statement 1 What is the Status of the Organisation? Analysis of Environment SWOT Analysis Matrix Analysis Formulation 2 What is the Desired State of the Organisation? Statement of Objectives Targets 3 How Will the Desired State be Achieved? Marketing Strategy Manufacturing Strategy I.T. Strategy Strategic Choice 4 Actions 5 Implementation Monitoring and Control 6 0110

  12. 01 SWOT Analysis/Matrix Analysis Strengths Weaknesses Opportunities Threats Engineering Students • Cows. These generate cash. • Calves. These consume cash, but will generate money in the future. • Dogs. These consume cash and always will. S – Well Qualified in Engineering as a Technical Discipline W – Lack of Business/Financial Knowledge to Achieve Promotion to Senior Management O – Solid Analytical Background Could Provide the Chance to Move into Systems/IT Related Areas T – Manufacturing Declining in the West and Wages Could be Further Depressed 0111

  13. Manufacturing Strategy Order Process Corporate Marketing Infrastructure Winning Strategy Strategy Choice Criteria • Processes • Financial • Innovation • Qualifying • Organisation • Growth • Markets • Inventory • Controls • Winning • Volumes • Variety • Mix 01 Corporate/Manufacturing Strategy 0112

  14. Transfer Line Batch Flow FMS Individual Machine FMC 01 Choice of Technology - 1 100,000 Volume Increasing Cost per Piece 10,000 Increasing Flexibility 1000 100 10 100 1,000 Variety 0113

  15. 01 Choice of Technology – 2 Soft Automation is Becoming Increasingly Common 0114

  16. System Controller Machine 1 Machine 2 Load Load Machine 2 Machine 3 Machining Pallets Machine 1 Machine 4 Robot Unload Unload Machine 6 Machine 5 01 FMS and FMC 0115

  17. 01 Flexible Assembly Line Manual Station Magazines Pallets Non-synchronous transfer machine Work carrier 0116

  18. 01 Flexible Assembly Cell Parts presented in pallet General purpose gripper Assembly robot Parts presented in magazines Conveyor for completed assembly Work fixture Gripper/Finger storage rack Conveyor for base parts Vibratory bowl feeder 0117

  19. 01 Equipment Layout - 1 Fixed Position 8 1 7 2 Equipment Types Material 1 - 8. 6 3 5 4 0118

  20. Equipment Layout - 2 01 Functional Drill Drill Lathe Lathe Drill Drill Lathe Lathe Mill Mill Grinder Grinder Grinder Grinder Mill Mill 0119

  21. Equipment Layout - 3 01 Group Flowline 1 Grinder Drill Lathe Lathe Lathe Drill Cell 1 Flowline 2 Mill Grinder Grinder Drill Mill Mill Flowline 3 Grinder Drill Mill Lathe Lathe Drill Cell 2 Flowline 4 Mill Grinder Grinder Drill Mill Lathe 0120

  22. Equipment Layout – 4 01 Flow Process Process Process Process 1 2 3 4 0121

  23. 01 Hierarchical Organisation – Example Corporate AutoComp plc Other Divisions Division AutoComp Braking Other Sites Site AutoComp Braking Products UK Original Equipment Business Unit Aftermarket Railways Press Cure Disc Brake Pads Press Form Disc Brake Pads Block Mixing Linings Plate Preparation Pressing Finishing Dept. Cell A Cell B Cell C Cell D Group Machine M/C 1 M/C 2 M/C 3 M/C 4 M/C 5 M/C 6 0122

  24. Geographical Location 01 • Proximity to Materials/Sub-Contractors • Proximity to Markets • Availability of Space • Quality of Infra-structure • Availability of Labour • Availability of Grants • Political Stability 0123

  25. 01 Functional Layout Design • Sometimes Called Process Orientated • Traditional Layout Method • Unfashionable, but has Several Advantages • Obligatory in Some Circumstances • Common in Service Environments • Layout is a Universal Problem 0124

  26. 01 Functional Layout Design • Physical Modelling • Computer Heuristic Methods • Simulation Methods • Cross and Relationship Charts 0125

  27. 01 Cross Chart Example To Process A B C D E F G H I J A 1635 200 65 50 50 2000 B 1600 35 1635 C 1750 25 25 1800 D 1815 1815 E 1775 40 1815 From Process F 1885 1885 G 2000 2000 H 1500 500 2000 I J 1635 1800 1815 1815 1885 2000 2000 1500 500 0126

  28. 01 Generation of a Cross Chart Number of Projected Product Product Sales Batches ADS1029 1000 ADS1029 10 Sales ASS5431 2000 ASS5431 10 DDF8897 2500 DDF8897 20 Planning HGF6509 1500 HGF6509 15 Data UAC9875 750 UAC9875 7 To Process A B C D E F G H I J Lot A 1635 200 65 50 50 2000 Product B 1600 35 1635 Size C 1750 25 25 1800 100 ADS1029 D 1815 1815 E 1775 40 1815 ASS5431 200 From Process Planning F 1885 1885 DDF8897 125 G 2000 2000 HGF6509 100 Data H 1500 500 2000 UAC9875 150 I J 1635 1800 1815 1815 1885 2000 2000 1500 500 Product Routing ADS1029 A B C D E F G H I A C F G H J ASS5431 Routing A B C D E F G H I DDF8897 A B C D E F G H J HGF6509 Data A F G H I UAC9875 0127

  29. 01 Layout Representation – 1 165 A B C A B E Minimise Non-Adjacent Loads D E F C D F 300 A B C D E F To From A 150 75 B 300 75 C 90 75 60 D 150 200 150 E 75 F 150 150 0128

  30. 01 Layout Representation – 2 • Minimises Transport Distances • An Iterative Process • Needs Quantitative Data • Can be Used for Service Layouts A B C D E F A B E C D F 0129

  31. 01 Relationship Chart To Process A B C D E F G H I J A A 1635 200 65 50 50 2000 A B 1600 35 1635 B E C 1750 25 25 1800 A I D 1815 1815 C E 1775 40 1815 U U From Process F 1885 1885 A U I G 2000 2000 D U O I H 1500 500 2000 A O U U I E U U U O J A U U U U 1635 1800 1815 1815 1885 2000 2000 1500 500 F I U U U A U U U Absolutely Important Ordinarily Important G U U U A O A U U H U U Especially Important E U Unimportant A U I A U Undesirable I X Important J 0130

  32. O A E U I X Tool R. Desp. Prod. 1 Prod. 1 Tool R. Off. Off. Prod. 2 R & D Prod. 2 Desp. R & D 01 Relationship Chart – Example A 2% to 5% E 3% to 10% I 5% to 15% O 10% to 25% U Remainder Production 1 A I Production 2 O U Offices A X I X E Despatch O E U U Original Revised R & D U U Tool Room • No “X” Lines 0131

  33. 01 Location of New Resources 0132

  34. Cost Surface 01 0133

  35. 01 Summary • Functional Layout has Advantages • Movement is Non-Value Adding • Many Techniques for Layout • Good Layout is Critical 0134

  36. 01 Cellular Manufacturing – Overview • No Universal Definition But Common Themes • A Grouping Within a Larger Organisation • Produces a Family of Products • Has Significant Autonomy • Self-Contained to Some Degree • Can be Measured Independently 0135

  37. 01 Functional Layout – Disadvantages • Distance Travelled by Components • High Levels of Material Handling • Queuing is Uncontrolled • High WIP • Long Lead Time • Difficult to Understand the System • Difficult to Simplify There Are Some Fundamental Disadvantages in Terms of Material Flow 0136

  38. 01 Group Technology Flowline 1 Grinder Drill Lathe Lathe Flowline 2 Grinder Drill Mill Mill Flowline 3 Grinder Drill Mill Lathe Flowline 4 Grinder Drill Mill Lathe 0137

  39. 01 Coding Systems - The Salford Method 4th Digit 5th Digit 6th Digit 1st Digit 2nd Digit 3rd Digit Geometry or Technological Complexity Tool Class External Shape Internal Shape Flange Detail Factor 0 Single Station Shape Definition Number 1 Number of Complexity Aperture Compound of Contour Factor Definition and/or Dias Vectors Flat, Bent, Hollow 2 Fine Combinations Blanking 3 Progressive 4 Transfer Definition Definition (Moving Punch) Complexity Flange of Number of Component Features Characteristics Factor of Dias and Reversal 5 Transfer Tapers (Moving Die) 6 Four Slide (Single) 7 Four Slide (Double) Number Definition Complexity Aperture Number of Contour of Contour 8 Factor Definition of Bends Vectors Special data 9 Production Flow Analysis was also Used 0138

  40. 01 GT Cells Flowline 1 Grinder Drill Lathe Lathe Lathe Drill Cell 1 Flowline 2 Grinder Mill Lathe Grinder Drill Mill Flowline 3 Grinder Drill Lathe Lathe Lathe Drill Cell 2 Flowline 4 Grinder Mill Lathe Grinder Drill Lathe 0139

  41. 01 Product/Process Matrix – 1 Product 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Process 15 0140

  42. 01 Product/Process Matrix – 2 A B C D Product 4 6 2 5 8 1 3 7 9 11 14 18 21 24 12 23 13 17 20 10 15 16 19 22 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Process 15 0141

  43. 01 Pre-Requisites for the GT Approach Both GT Flowlines and GT Cells Might be Called “Cells” Today • Natural Product Groups • Light Components • Few Indivisible Processes • A Stable Product Mix • Cross Skilled Personnel/Excess Machine Capacity • Willingness to Undertake Variety Reduction • Availability of Funds Inappropriate Use of GT Can Reduce Utilisation and Flexibility 0142

  44. Capacity and Flowlines Work Centre 1 Work Centre 2 Work Centre 3 01 12 Units/Hr 5 Mins/Unit 10 Units/Hr 6 Mins/Unit 12 Units/Hr 5 Mins/Unit • Overall Production Rate = 10 Units per Hour • Simple Case – Slowest Work Centre Determines Rate 0143

  45. 01 Multi-Machine Manning How Should Labour be Allocated? 0144

  46. Line Balancing - Precedence Diagram 01 3.2 E 4.5 2.0 6.0 I B F 2.5 3.5 2.7 3.8 4.3 L A C G J 4.0 7.0 5.0 D H K Particularly Applied for Repetitive Assembly Problems 0145

  47. Element (Min) Time Preceded By A 2.5 B 4.5 A C 3.5 A D 4.0 A E 3.2 B F 2.0 B, C G 2.7 D H 7.0 D I 6.0 E J 3.8 F, G K 5.0 H L 4.3 I, J, K 01 Line Balancing – Precedence Table Same Data as Previous Slide But in Tabular Form 0146

  48. Largest Candidate Method - 1 A 1 2.5 B 7.0 4.5 2 D 4.0 C 3.5 F 2.0 9.5 3 H 7.0 G 2.7 9.7 4 K 5.0 J 3.8 8.8 5 E 3.2 I 9.2 6.0 6 L 4.3 4.3 01 3.2 E Work Centre Sum 4.5 2.0 6.0 Work Centre Element Time I F B 3.5 2.7 2.5 3.8 4.3 C G A J L 5.0 4.0 7.0 K H D H 7.0 I 6.0 K 5.0 B 4.5 L 4.3 D 4.0 Elements Sorted into Size Order J 3.8 C 3.5 E 3.2 G 2.7 A 2.5 F 2.0 0147

  49. 01 Largest Candidate Method – 2 Twc = Total of All Elements d = Balance Delay (or Balance Loss) In the previous example, Twc = 48.5 and n = 6 0148

  50. 3.2 E 4.5 2.0 6.0 I F B 3.5 2.7 2.5 3.8 4.3 C G A J L 5.0 4.0 7.0 K H D 01 RPW Method – 1 • Ranked Positional Weight (RPW) Similar to Largest Candidate • Only Difference is in Choosing Elements • The RPW Value for an Element is the Sum of “Downstream” Elements Examples of RPW Calculations RPW for J = J + L = 8.1 Minutes RPW for F = F + J + L = 10.1 Minutes RPW for B = B + E + I + L + F + J = 23.8 Minutes Thus to Find the RPW value for an Element, Trace All of the Paths Through the Network to the End 0149

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