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Chapter 6 Process Selection and Facility Layout

Chapter 6 Process Selection and Facility Layout. What is designing a television? TV at RANGS Making sandwiches!. Deciding on the way production of goods or services will be organized

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Chapter 6 Process Selection and Facility Layout

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  1. Chapter 6Process Selection and Facility Layout What is designing a television? TV at RANGS Making sandwiches!

  2. Deciding on the way production of goods or services will be organized A process is any part of an organization that transforms inputs into outputs, with the intention that the output will be of greater value than the input. Process selection

  3. Flowchart for a new product development process

  4. Process Selection and System Design- Figure 6.1 Forecasting Facilities andEquipment CapacityPlanning Layout Product andService Design ProcessSelection TechnologicalChange WorkDesign

  5. Process Strategy

  6. Exam OM & Technology Competitive Advantage

  7. Exam

  8. Process Selection

  9. Few Major Products, Higher Volume High Volume, High Standard- ization Low Volume One of a Kind Multiple Products, Low Volume Job Shop Book Writing Batch Movie Theaters Assembly Line Automobile Assembly Continuous Flow Sugar Refinery Flexibility-Quality Dependability-Cost Process Types and Product-Process Matrix

  10. Linking key product or service requirements to process capabilities Product Profiling

  11. Automation: Machinery that has sensing and control devices that enables it to operate • Fixed automation: Low production cost and high volume but with minimal variety and high changes cost • Assembly line • Programmable automation: Economically producing a wide variety of low volume products in small batches • Computer-aided design and manufacturing systems (CAD/CAM) • Numerically controlled (NC) machines / CNC • Industrial robots (arms)

  12. Automation: Machinery that has sensing and control devices that enables it to operate … • Flexible automation: Require less changeover time and allow continuous operation of equipment and product variety • Manufacturing cell • Flexible manufacturing systems: Use of high automation to achieve repetitive process efficiency with job shop process • Automated retrieval and storage • Automated guided vehicles • Computer-integrated manufacturing (CIM)

  13. Robot

  14. Movie Break

  15. Group of machines that include supervisory computer control, automatic material handling, robots and other processing equipment Advantage: reduce labor costs and more consistent quality lower capital investment and higher flexibility than hard automation relative quick changeover time Disadvantage used for a family of products and require longer planning and development times Flexible Manufacturing System

  16. Use integrating computer system to link a broad range of manufacturing activities, including engineering design Purchasing order processing production planning and control … Advantage: rapid response to customer order and product change, reduce indirect labor cost, high quality Computer-integrated manufacturing

  17. Establish boundaries Identify steps involved Prepare a flowchart Identify potential failure points Establish a time frame for operations Analyze profitability Service Process Design

  18. The configuration of departments, work centers, and equipment, with particular emphasis on movement of work (customers or materials) through the system Facilities Layout

  19. Facilitate attainment of product or service quality Use workers and space efficiently Avoid bottlenecks Minimize unnecessary material handling costs Eliminate unnecessary movement of workers or materials Minimize production time or customer service time Design for safety Exam Objective of Layout Design

  20. The Need for Layout Decisions • Inefficient operations • High Cost Bottlenecks • The introduction of new products or services • Changes in the design of products or services • Accidents • Safety hazards • Changes in environmental/legal requirements • Changes in methods and equipment • Changes in volume of output or mix of products • Morale problems

  21. Combination Layouts

  22. Exam Figure 6.4 | Product Layout Raw materials or customer Station 1 Station 2 Station 3 Station 4 Finished item Material and/or labor Material and/or labor Material and/or labor Material and/or labor Used for Repetitive or Continuous Processing

  23. A U-Shaped Production Line 1 2 3 4 In 5 Workers 6 Out 10 9 8 7

  24. Dept. A Dept. C Dept. E Dept. B Dept. D Dept. F Exam Process Layout- functional Milling Assembly& Test Grinding Used for Intermittent processing Job Shop or Batch Processes Drilling Plating Process Layout - work travels to dedicated process centers

  25. Layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed. Fixed Position Layouts

  26. Group Technology Layout • The grouping into part families of items with similar design or manufacturing characteristics. Each cell is assigned a family for production. This limits the production variability inside cells, hence allowing for a product layout. Part Family W Part Family X Part Family Z Assemble Y,W Assemble X,Z Part Family Y Final Product • Similar to cellular layout Similar manufacturing characters

  27. Exam Process vs. Cellular Layouts

  28. Other Layout • Cellular Manufacturing • Layout in which machines are grouped into a cell that can process items that have similar processing requirements. A product layout is visible inside each cell. • Combination Layouts: combination of three pure types. Example: hospital: process and fixed position.

  29. Warehouse and storage layouts Retail layouts Office layouts Service layouts must be aesthetically pleasing as well as functional Service Layouts

  30. Design Product Layouts: Line Balancing • Line Balancing is the process of assigning tasks to workstations in such a way that the workstations have approximately equal time requirements. • Determine Maximum Output • Example: If a student can answer a multiple choice question in 2 minutes but gets a test with 30 questions and is given only 30 minutes then • OT=30 minutes; D=30 • Desired cycle time=1 minute < 2 minutes = Cycle time from the process capability

  31. Determine Maximum Output Cycle time is the maximum time allowed at each workstation to complete its set of tasks on a unit.

  32. Determine the Minimum Number of Workstations Required: Efficiency • Example: Students can answer a multiple choice question in 2 minutes but given a test with 30 questions and is given only 30 minutes. What is the minimum number of students to collaborate to answer all the questions in the exam? • Total operation (task) time = 60 minutes = 30 x 2 minutes • Operating time=30 minutes • 60/3=2 students must collaborate. This Nmin below.

  33. Calculate Percent Idle Time Efficiency = 1 – Percent idle time

  34. 3.1 min. 7.2 min. a b c d e 2.7 min. 4.5 min. 10 min. Precedence Diagram | Figure 6.11 • Precedence diagram: Tool used in line balancing to display elemental tasks and sequence requirements Exam

  35. Example 1: Assembly Line Balancing • Arrange tasks shown in Figure 6.10 into three workstations. • Use a cycle time of 1.0 minute

  36. 0.1 min. 1.0 min. Example 1 Solution a b c d e 0.7 min. 0.5 min. 0.2 min.

  37. 0.1 min. 1.0 min. a b c d e 0.7 min. 0.5 min. 0.2 min.

  38. h c d a b e f g Example 2 | CT = 1.2 min 0.2 0.2 0.3 0.8 0.6 1.0 0.4 0.3

  39. Station 1 Station 2 Station 3 Station 4 a b e g h f c d Solution to Example 2

  40. 30/hr. 30/hr. 30/hr. 30/hr. 1 min. 1 min. 2 min. 1 min. Bottleneck Bottleneck Workstation

  41. 2 min. 30/hr. 30/hr. 60/hr. 60/hr. 1 min. 1 min. 1 min. Parallel Workstations 30/hr. 30/hr. 2 min. Parallel Workstations

  42. The difficulty to forming task bundles that have the same duration. The difference among the elemental task lengths can not be overcome by grouping task. Ex: Can you split the tasks with task times {1,2,3,4} into two groups such that total task time in each group is the same? Ex: Try the above question with {1,2,2,4} A required technological sequence prohibit the desirable task combinations Ex: Let the task times be {1,2,3,4} but suppose that the task with time 1 can only done after the task with time 4 is completed. Moreover task with time 3 can only done after the task with time 2 is completed. How to group? The obstacle

  43. Designing Process LayoutsInformation Requirements • List of departments- easy • Shape requirements • Projection of work flows- easy? • One way vs. two way: Packaging and final assembly. • Distance between locations- easy • One way vs. two way: Conveyors, Elevators. • Amount of money to be invested- easy? • List of special considerations- easy? • Technical, Environmental requirements

  44. Example 3: Locate 3 departments to 3 sites • Distances: in meters • Work Flow: in kilos

  45. Mutual flow: Closeness graph: Example 3 Ranking locations & Departments 1 2 3

  46. 30 170 100 W1 W2 W3 A B C Example 3: Interdepartmental Work Flows for Assigned Departments Figure 6.13

  47. Create Layout Alternatives Find the one which minimizes transportation costs and distance traveled Designing Process Layouts

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