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Production Systems Design

Production Systems Design. Types of Production Systems. Outline. Important Considerations. Types of Production Systems. Characteristics. Pros and cons. To design a facility, we need to know. Flow. How do things move around?. Space. How much room do we need?. Activity Relationships.

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Production Systems Design

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  1. Production Systems Design Types of Production Systems

  2. Outline Important Considerations Types of Production Systems Characteristics Pros and cons.

  3. To design a facility, we need to know Flow How do things move around? Space How much room do we need? Activity Relationships Close together or far apart?

  4. How do things move around? (Flow) Lot sizes Unit load sizes MH Equipment Layout arrangements Building Configurations

  5. How much room do we need? (Space) Lot sizes Storage systems Production Equipment Layout arrangements Building Configurations Personnel areas

  6. Close together or far apart? (Relationships) Material Flow Personnel flow Environmental Teamwork Process Requirements

  7. The Type of Production System affects Flow, Space and Relationships… Product Layout High Group Technology Layout Production Volume Medium Fixed Location Layout Process Layout Low Low Medium High Product Variety

  8. Fixed Location Layout Low, sporadic demand Large products Hard (or impossible) to move Highly customized

  9. “Have them come to me” People and equipment come to the product

  10. What to do? Bring personnel and equipment to the product Combine all workstations withthe staging area for the product Product

  11. Product Layout Designed for a specific product Flow Lines Sequential arrangement of equipment High demand, low variety

  12. What does a Product Layout look like? T T M D G Standardized product Combine all workstations required to manufacture a product Large, stable demand

  13. Characteristics of Product Layout Very fast – High throughput Short lead times Low WIP Can be automated Higher consistency Specific for one product Low flexibility

  14. Process Layout (or Job Shop) Higher variety Moderate to low volumes Not enough demand to dedicate equipment

  15. Solution P P G G Organize depts. according to processes G G B B D D Machines with similar capabilities and functions D D T M M Batches might use different tooling and setups: High skill levels T M M T

  16. Characteristics of Process Layout Long throughput times High WIP Crossed Product routings Harder MH and transportation Higher Machine utilization Process knowledge accumulation (in the workers)

  17. Group technology Similar parts (product families) Enough to justify dedicated equipment Might have similar routings Groupings not according to physical appearance

  18. Organize cells ! T M Configure a cell for each product family M G D D B Dedicate a set of machines in a designated physical area M D

  19. Characteristics of cellular layouts More than one machine per operator 1 2 3 Low WIP 4 Faster response to quality problems 5 Shorter Throughput time 8 7 6 Easier scheduling and control

  20. In summary… Throughput Time W.I.P. Mixed Skill Level Choice Product Flexibility Demand Flexibility Machine Utilization Worker Utilization Unit Production Cost High Low Medium Medium-High Medium-Low Characteristic Product Process Group Fixed Position

  21. What type of process would go better with… Fast Food Restaurant? Hospital? Airport? Mall? (points of view of the consumer and the stores)

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