ENG408 - Presentation 04

8/8/2019 ENG408 - Presentation 04

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,low Space and low Space and ctivity Relationships ctivity Relationships

I

epartmental Planningepartmental Planning



,ow Space an Activity w pace an ct v ty elationships elationships

Flow ,Flow into within and from manufacturing

facility , , ,Flow of materials people equipment

, , .information money etcSpace

The amount of space required in thefacility , Workstation specification department

specification and other spacerequirements

Activity relationships Activity relationship is the key input in facilities design

,Defined by flow relationships,organizational relationships,environmental relationships process

relationships and control relationships



lanning department definition lanning department definition ::

Ø A collection of workstations that are

grouped together during the layout.process

Ø “ ” .Often they perform like functions “ ”Like may mean Similar products Similar processes



:Planning department Examples:Planning department Examples

Production - , , .Machining Assembly etcSupport - ,Maintenance Tool and

, , .Die Quality Assurance etcAdministrative - ,Accounting Human

, .Resources etc

Service - , , .Cafeteria Restrooms etc

We need to know three things about a planningdepartment

.1 What is done there? .2 What is its relationship with other

departments? .3 How big is it?



Manufacturing methodologies change Manufacturing methodologies change

Shipping/Receiving Docks

Storage Spaces

Storage-In

S t o

r a g e

- O

u t

Storage-In

S t o

r a g e

- O

u t

S t o

r a g e

- I n

S t o

r a g e

- O u t



Supplier

Shipment without QC

Manufacturer

Qualitycontrol Defects

Supplier

Supplier

Shipment after QC

Manufacturer

Qualitycontrol Defects

Supplier

Manufacturing methodologies change Manufacturing methodologies change



Current manufacturing:practices

Decentralized storages Multiple receiving docks Deliveries to points of us Decentralized management

and support functions Quality control at the

source Cellular manufacturing Lean organizational

structures Small lot purchasing and

production

Traditional practices that are not desirable

today Centralized offices Centralized storage

spaces Single receiving area Centralized rework

stations

cilities design principles should adopt to the cha



Product layout (Flow shop)

Fixed product layout

Process layout (Job shop)

Group layout



Departmental planningDepartmental planning

Product Layout ombining workstationsStandardized Large stabledemand

roduct ayout

( )flow shop

Combine all workstations required to produce the

product Physically large Awkward to move Low sporadicdemand

ixed roduct

layout


product with the area

required for staging theproduct

Capable of being grouped into

families of similar parts

roup layout(product

)family layout


family of products

None of the above rocess

epartment( )job shop

Combine identical

workstations intodepartments Combine similardepartments



–Group Technology Cellular–Group Technology CellularManufacturingManufacturing

( ) Group technology product family departments

-aggregate medium volume variety parts into families based on imilar manufacturing

.perations and design attributes

Similar design attributes, Different design attributes,different manufacturing requirements similar manufacturing requirements



Group Technology – Cellular Group Technology – Cellular ManufacturingManufacturing

Group technology (product family) departmentsaggregate medium volume-variety parts into familiesbased on similar manufacturing operations anddesign attributes.



–Group Technology Cellular–Group Technology CellularManufacturingManufacturing

Manufacturing cells

, ,group machines employees

,materials tooling and material handling and.storage equipment to produce families of parts

Manufacturing cell operation needs minimum externalsupport

,Often designed controlled and operated using JIT :Benefits of cell manufacturing

:eduction , , ,inventories space paperwork, , .equipment transportation etc

:implification , ,communication handling

, .scheduling etc Improvement: , ,productivity flexibility

, , .quality customer satisfaction etc



Cellular ManufacturingCellular Manufacturing

Machine1

Machine

2 Machine3

Machine4Machine

5

Materials in

Finishedgoods out

Dissimilar Dissimilar machines grouped to producedmachines grouped to producedSAME Family ProductsSAME Family Products

B f GT



© Wiley 2007

Before GT

After GT



B e f o r ee f o r e : r o c e s s L a y ou t: ro c e s s L a y o ut

Drilling

D D

D D

Grinding

G G

G G

G G

Milling

M M

M M

M M

Assembly

A A

A A

Lathing

Receiving andshipping

L

L L

L L

L L

L

Jumbled flows in a job shop without GT cellsJumbled flows in a job shop without GT cells



:f t e r :f t e r r o u p r o u p

T e c h n o l o g ye c h n o l o g y

Cell 3

L M G G

Cell 1 Cell 2

Assemblyarea

A A

L M DL

L M ShippingD

Receiving

G



Group parts together so that

they can be processed as a

family Links parts and

machines in

-machine partmatrixMachine-part matrix



Group parts together so that they can be

processed as afamily

Links parts and machines in -machine part matrix

Machine-part matrix



.1 -Form machine part matrix

.2 Sum the 1 &s in each column row

.3 Order the rows in descending order

.4 Order the columns in ascending

order.5 (Sort the columns 1 in the first,row moves left then in the

, .)second row etc

.6 (Sort the rows 1 in the first,column moves upward then in the, .)second column etc

.7 Form cells



Direct clustering algorithmDirect clustering algorithm

2. Sum the 1s in eachcolumn & row

3. Order the rows indescending order

4. Order the columns inascending order

1




5. Sort the columns (1 in the first row movesthe column to the left, then 1 in the secondrow, etc.)

2




6. Sort the rows (1 in the first column moves therow upward, then 1 in the second column, etc.)



irect clustering algorithm irect clustering algorithm “ ”ottleneck machines“ ”ottleneck machines

Machine 2 which is needed for# #parts 3 and 5 creates

!conflicts

DCA



irect clustering algorithm irect clustering algorithm “ ”ottleneck machines“ ”ottleneck machines

Machine 2 which is needed for# #parts 3 and 5 creates

!conflicts

What can we do?



4 2 3a 3b 1

Duplicated machine 2 Duplicated machine 3



DCA



Create only 2cells

Place the bottleneck

machines at the

boundary of

the cells

Duplicate the bottleneck

machines

n the problem be solved by redesigning or outsour



Cl Id ifi iCl t Id tifi ti



P1 P2 P3 P4 P5 P6 P7 P8

M1 1 1 1

M2 1 1

M3 1 1

M4 1

M5 1

M6 1

M7 1 1 1

1 1 1

Cluster Identification Cluster IdentificationAlgorithmAlgorithm



Cl t Id tifi tiCl t Id tifi ti



P1 P2 P3 P4 P5 P6 P7 P8

M1 1 1 1

M2 1 1

M3 1 1

M4 1

M5 1

M6 1

M7 1 1 1 1

1 1 1

1 1





.4 Repeat until all the 1s are crossed

by a vertical line or by a horizontalline

P1 P2 P3 P4 P5 P6 P7 P8

M1 1 1 1

M2 1 1

M3 1 1

M4 1

M5 1

M6 1

M7 1 1 1

1 1 1

1 1 1

1





.5 Form a cell from all the machines and

components which were crossed

P2 P3 P5 P8

M1 1 1 1

M5 1

M7 1 1 1

!First cell is identified# , ,Cell 1 will produce parts P2 P3 P5

,and P8 with Machines M1 M5 and M7


Cl t Id tifi tiCluster Identification



.6 Remove all the crossed elements

( )machines and components and startagain

P1 P4 P6 P7

M2 1 1

M3 1 1

M4 1

M6 1

P1 P6

M2 1 1

M4 1

#Cell 2 will produce parts P1 and P6 with Machines M2 and M4

1 1

1





.6 Remove all the crossed elements

( )machines and components and startagain

P4 P7

M3 1 1

M6 1

P4 P7

M3 1 1

M6 1

#Cell 3 will produce parts P4 and P7 with Machines M3 and M6

1

1

1


ENG408 - Presentation 04

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