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Methods, Standards, and Work Design11th Edition

Niebel/Freivalds

Products and Facilities

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Concurrent EngineeringDefined Concurrent engineering

– the simultaneous development of project design functions

– open and interactive communication existing among all team members for the purposes of:» reducing time to market, » decreasing cost, and » improving quality and reliability

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Design for Manufacturing and Assembly

Greatest improvements related to DFMA arise from simplification of the product by reducing the number of separate parts:

» 1. During the operation of the product, does the part move relative to all other parts already assembled?

» 2. Must the part be of a different material or be isolated from other parts already assembled?

» 3. Must the part be separate from all other parts to allow the disassembly of the product for adjustment or maintenance?

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Types of Processes

Conversion - changing iron ore into steel

Fabrication - making car bumpers from plastic

Assembly - assembling a car

Testing - computer boards - not a fundamental process

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Process Flow Structures Job shop - small batches of a large number of different

products– printing, machine shop, tool & die

Batch shop - standardized job shop, products produced in batches– clothing

Assembly Line - parts move from station to station at a controlled rate– microwaves, cars

Continuous Flow - continuous versus discrete flow – beer, paint

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IV.Continuous

Flow

III.Assembly

Line

II.Batch

I.Job

Shop

LowVolume,One of a

Kind

MultipleProducts,

LowVolume

FewMajor

Products,HigherVolume

HighVolume,

HighStandard-

ization

CommercialPrinter

French Restaurant

HeavyEquipment

Coffee Shop

AutomobileAssembly

Burger King

SugarRefinery

Flexibility (High)Unit Cost (High)

Flexibility (Low)Unit Cost (Low)

Exhibit 5.10Exhibit 5.10

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Basic Production Layout Formats

Process Layout

Product Layout

Group Technology (Cellular) Layout

Fixed-Position Layout

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Flow Through Systems

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Process-Oriented Layout

Design places departments with large flows of material or people together

Dept. areas have similar processes– e.g., All x-ray machines in same area

Used with process-focused processes Examples

– Hospitals– Machine shops

© 1995 Corel Corp.

10

Process-Oriented Layout Floor Plan

OfficeOffice

Tool RoomTool Room

Drill PressesDrill Presses

Table SawsTable Saws

© 1995 Corel Corp.

© 1995 Corel Corp.

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Product-Oriented Layout

Facility organized around product Design minimizes line imbalance

– Delay between work stations Types: Fabrication line; assembly line Examples

– Auto assembly line– Brewery– Paper mfg. © 1984-1994 T/Maker Co.

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1 3

2

4

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Product-Oriented Layout Floor Plan

OfficeOffice

Belt Belt ConveyorConveyor

Operations

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Cellular Layout - Group Technology (Work Cells)

Special case of process-oriented layout Consists of different machines brought

together to make a product Group Technology Benefits:

– Better human relations – Improved operator expertise – Less in-process inventory and material handling– Faster production setup

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Work Cell Floor Plan

OfficeOffice

Tool RoomTool RoomWork CellWork Cell

SawsSaws DrillsDrills

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Fixed-Position Layout

Design is for stationary project Workers & equipment come to site Complicating factors

– Limited space at site– Changing material needs

Examples– Ship building– Highway construction

© 1995 Corel Corp.

© 1995 Corel Corp.

© 1995 Corel Corp.

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Fixed Position Layout

Question: What are our primary considerations for a fixed position layout?

Answer: Arranging materials and equipment concentrically around the production point in their order of use.