1 / 30

Park, Mok-Min 2005.05.20 MAILab. Seminar

nerice
Download Presentation

Park, Mok-Min 2005.05.20 MAILab. Seminar

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. Next Generation Factory Layouts:Research Challenges and Recent ProgressSaif Benjaafar1, Sunderesh S. Heragu2, Shahrukh A. Irani31Graduate Program in Industrial Engineering, Dept. of Mechanical Eng., Univ. of Minnesota, Minneapolis, Minnesota2 Dept. of Decision Science and Eng. Sys.,Rensselaer Polytechnic Institute, Troy, New York3 Dept. of Industrial and Systems Eng., Ohio State Univ., Columbus, OhioINTERFACES, Vol.32, No.6, Nov-Dec 2002, pp. 58-76 Park, Mok-Min 2005.05.20 MAILab. Seminar

  2. Contents • About Authors • About References • Introduction • Literature Review • Layout Classification • Emerging Trends in Industry • Next Generation Factory Layouts • Research Challenges • Discussions MAILab. Seminar

  3. About Authors Saif Benjaafar 1995 Machine sharing in cellular mfg sys. 2000 Flexible factory layouts 2000 Design of flexible plant layouts 2002 Design of plant layouts w/ queueing effects 2002 Design of dynamic distributed layouts Sunderesh S. Heragu 1987 The facility layout problem 1994 Group tech. and cellular mfg. 1994 Material handling issues is adaptive mfg. sys. 1999 Facility layout design in a changing environment 2000 A framework for designing reconfigurable facilities 2000 An open queuing network approach to evaluating cellular and job shop layouts Shahrukh A. Irani 1993 Custom design of facility layouts for multi-product facilities using layout modules 2000 Virtual mfg cells: Exploiting layout design and intercell flows for the machine sharing problem MAILab. Seminar

  4. About References MAILab. Seminar

  5. About References MAILab. Seminar

  6. Introduction Limits of conventional layouts Limits of current design criteria • Existing layout configurations do NOT • meet the needs of multi product • enterprises • There is a need for a new generation of • factory layouts that are more flexible, • modular, and easy to reconfigure MAILab. Seminar

  7. Introduction Limits of conventional layouts Limits of current design criteria • Current design criteria • Do NOT capture the effect of layout on operational • performance (cycle time, WIP, throughput) • Ignore the impact of operational parameters (setup, batching, loading/unloading at work centers) • Measure only average performance and in so doing • cannot guarantee effectiveness under all operating • scenarios MAILab. Seminar

  8. LiteratureReview • Dynamic facility-layout problem • 1976 – costs of relocating departments in analyzing a single period problem • 1986 – optimal layouts for multiple period • 1991~1994 – variations of the basic dynamic layout problem • 1993~1998 - heuristics MAILab. Seminar

  9. Literature Review • Robustness • 1987 – concept of robustness • 1992 – heuristic strategies for developing robust layouts for multiple planning periods • Flexible layouts • 1992 – method for developing flexible layouts MAILab. Seminar

  10. Layout Classification Robust layouts for multiple production periods/scenarios Assume that production data is available at the initial design stage Be unlikely in a dynamic environment (responsiveness) Flexible/modular layouts Assume that layouts would be reconfigured after each period Should be designed to minimize reconfiguration costs while guaranteeing reasonable material-flow efficiency in each period (cost) MAILab. Seminar

  11. Layout Classification • Design criteria • Expected material-handling efficiency (mean) • Robustness criterion (variance) • Operational performance MAILab. Seminar

  12. Layout Classification MAILab. Seminar

  13. Emerging Trends in Industry • Contract Manufacturing • Delayed Product Differentiation • Multichannel Manufacturing • Scalable Machines • Portable Machines MAILab. Seminar

  14. Contract Manufacturing • Spine layout • The configuration allows the plant to add and remove suppliers without changing the main layout. • High efficiency at the core and flexibility and reconfigurability at the periphery MAILab. Seminar

  15. Next Generation Factory Layouts • Distributed layouts • Modular layouts MAILab. Seminar

  16. Distributed Layouts • Disaggregate large functional departments into subdepartments • Hedge against future fluctuations in job-flow patterns and volumes • Reduce material-travel distances for many production flow sequences MAILab. Seminar

  17. Distributed Layouts MAILab. Seminar

  18. Distributed Layouts MAILab. Seminar

  19. Distributed Layouts • Help a firm to handle products with short runs or products with short life cycles • Can be useful in handling production growth and contraction • The firm can modify capacity in small increments since introducing or removing capacity takes place at the periphery MAILab. Seminar

  20. Modular Layouts • Modular layouts are hybrid layouts for systems with complex material flows that cannot be described as functional, flow line, or cellular. • Irani and Huang(2000) were first to introduce the concept of layout as a network of basic modules. • Irani and Huang designed a modular layout for a Motorolar facility using a visual string-matching analysis. MAILab. Seminar

  21. Modular Layouts MAILab. Seminar

  22. Modular Layouts • Design procedure for modular layouts • Extract the common substrings b/w all pairs of routings • Compute the frequency with which each common substring occurs in the routings • Aggregate similar substrings and create a layout module for each cluster of substrings • Eliminate modules that do not meet criteria for machine utilization or constraints on machine allocation and duplication among multiple modules MAILab. Seminar

  23. MAILab. Seminar

  24. Example Irani and Huang(2000), Custom Design of Facility Layouts for Multiproduct Facilities Using Layout Modules MAILab. Seminar

  25. Example MAILab. Seminar

  26. Example MAILab. Seminar

  27. Example MAILab. Seminar

  28. Research Challenges • Distributed layout • Integrated model that combines department duplication and capacity assignment with layout design and flow allocation • Capturing setup minimization in the objective function or placing additional constraints on flow allocation to prevent order splitting • Modularlayout MAILab. Seminar

  29. Research Challenges • Distributed layout • Modularlayout • Determining the optimal number of modules is the final layout • Establishing feasibility criteria for allocating machines to several modules subject to machine utilization • Comparing the performance of this new layout with those of flowline, cellular, and functional layout MAILab. Seminar

  30. Discussions • Modular layout에서 module을 파악한 뒤 이들을 어떻게 배치할 것인가도 중요한 문제인데, geometrical allocation 문제에 대한 해답이 없다. • Modular layout에서 routing이 변경되는 경우, module이 바뀔 수 있는가? • 일반적으로 module이란 공통된 routing의 집합이라고 할 수 있다. 따라서 기존의 routing과 완전히 다른 경우가 아닌 경우에는 기존의 module에 추가적인 operation만 추가하는 것으로 add나 reconfiguration 이 가능하다 MAILab. Seminar

More Related