WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
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IE 173: FACILITIES PLANNING AND DESIGN
Lecture Notes #2
Product, Process and Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
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Facilities Planning Process
1. Define the products to be manufactured
2. Specify the manufacturing processes and related activities required to produce the products
3. Determine the interrelationships among all activities
4. Determine the space requirements for all activities
5. Generate alternative facilities plans
6. Evaluate the alternative facilities plan
7. Select the preferred facilities plan
8. Implement the facilities plan
9. Maintain and adapt the facilities plan
10. Update the products to be manufactured and redefine the objective of the facility
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
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Questions before FP
What is to be produced?
How are the products to be produced?
When are the products to be produced?
How much of each product will be produced?
For how long will the products be produced?
Where are the products to be produced?
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
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Relationship of PP&S
Product
Design
Process
Design
Facilities
Design
Schedule
Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
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Product Design
The determination of which products are to be produced
The detailed design of individual products Aesthetics
Function
Materials
Man
Need help from other depts. Marketing, Purchasing, IE, Mfg, Product Engg, Quality Control
Using Quality Function Deployment
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Exploded assembly drawing
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Product Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Exploded part photograph
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Product Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Component part drawing
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Product Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Computer Aided Design (CAD)
Creation and manipulation of design prototypes
Area measurement
Building and interior design
Block and detailed layouts of manufacturing systems
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Product Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Concurrent Engineering
70% of manufacturing costs on design
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Product Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Responsible for determining how the product is to be produced
Who should do the processing: in-house or subcontracted make-or-buy decision
How the part will be produced
Which equipment will be used
How long it will take to perform the operation
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Process Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Parts List
Part numbers
Part name
Number of parts per product
Drawing references
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Process Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Parts List
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Process Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Bill of Materials
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Process Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Bill of Materials
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Process Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Process selection procedure
Step 1: Define elemental operations
Step 2: Identify alternative processes for each operation
Step 3: Analyze alternative processes
Step 4: Standardize processes
Step 5: Evaluate alternative processes
Step 6: Select processes
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Process Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Route Sheet
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Process Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Assembly Chart
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Process Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Operation Process Chart
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Process Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Precedence Diagram
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Process Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Elements Lot sizing (how much to produce)
Production scheduling (when to produce)
Product life status (how long to produce)
Dynamic vs Static Design Demand Volatility
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Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Machine selection
Number of machines
Number of shifts
Number of employees
Space requirements
Material handling equipment
Personnel requirement
Storage policies
Unit load design
Building size
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Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Marketing Information
Stochastic nature
Volume, trend and predicability
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Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
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Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Paretos Law
80% of the product volume
20% of the product line
Volume-variability chart
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Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Process requirements
Production Requirements (rejects and scrap)
Equipment Fractions
Total Machine Requirements
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Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Production Requirements
Output = Input - Defects
=
= /(1 )
For products with 2 sequential processes
= 1 1 (1 2)
= /[ 1 1 (1 2)]
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Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Problem #1
A product has a market estimate of 97,000 components and requires three processing steps (turning, milling, and drilling) having scrap estimates of P1=0.04, P2=0.01, P3=0.03. Calculate the production input to operation 1.
Answer: 105,219
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Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Problem #2
Answer: 103,280
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Schedule Design
?????
3%
40%
2%
Rework
100,000
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Equipment Fractions
=
M = number of machines required per period
t = standard time per unit produced
Q = quantity to be produced
P = actual performance, expressed as % of t
A = available time per machine
R = reliability of machine / up-time
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Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Problem #3
A machine part has a machinery time of 2.8 min per part on a milling machine. During an 8-hr shift, 200 units are to be produced. Of the time available for production, the milling machine will be operational 80% of the time. During the time the machine is operational, parts are produced at a rate equal to 95% of the standard rate. How many milling machines are required?
Answer: 2 machines
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Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Assignment #1
During one 8-hour shift, 750 nondefective parts are desired from a fab operation. The standard time for the operation is 15 min. Because the machine operators are unskilled, the actual time it takes to perform the operation is 20 min and, on the average, one-fifth of the parts that begin fabrication are scrapped. Assuming that each of the machines used for this operation will not be available for 1 hr each shift, determine the number of machine required.
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Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Question
Part X requires machining on a milling machine (operations A and B are required). Find the number of machines required to produce 3000 parts per week, 18 hours per day. The following information is known:
Extension: If the milling machine requires tool changes and PM after every lot of 500 parts. These changes require 30 mins
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Schedule Design
Operation Standard Time
Efficiency Reliability Scrap
A 3 min 95% 95% 2%
B 5 min 95% 90% 5%
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Total Machine Requirements
Machine assignment problem
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Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
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Schedule Design
Multiple activity chart
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
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Schedule Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
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Schedule Design
Cost Determination
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Once all PP&S decisions have been made, next will be:
Layout
Handling
Storage
Unit Load Design
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Facilities Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Affinity Diagram - used to gather verbal data
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Facilities Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Interrelationship diagram - used to map the logical links among related items, trying to identify which items impact others the most.
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Facilities Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Tree diagram - used to map in increasing detail the actions that need to be accomplished in order to achieve a general objective
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Facilities Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Matrix diagram - organizes information such as characteristics, functions, and tasks into sets of items to be compared
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Facilities Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Contingency diagram - formally known as process decision program chart, maps, conceivable events and contingencies that might occur during implementation. It particularly is useful when the project being planned consists of unfamiliar tasks.
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Facilities Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Activity network diagram - used to develop a work schedule for the facilities design effort. This diagram is synonymous to the critical path method (CPM) graph. It can also be replaced by a Gantt chart.
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Facilities Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Prioritization Matrix Layout characteristics
Total distance travelled
Manufacturing floor visibility
Overall aesthetics of the layout
Ease of adding future business
Material handling requirements
Use of current material handling equipment
Investment requirements on new equipment
Space and people requirements
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Facilities Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Prioritization Matrix Unit load implied
Impact on WIP levels
Space requirements
Impact on material handling equipment
Storage strategies
Space and people requirements
Impact on material handling equipment
Human factor risks
Overall building impact
Estimated cost of the alternative
Opportunities for new business
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Facilities Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Prioritization Matrix A. Total distance travelled
B. Manufacturing floor visibility
C. Overall aesthetics of the layout
D. Ease of adding future business
E. Use of current MH equipment
F. Investment in new MH equipment
G. Space requirement
H. People requirement
I. Impact on WIP level
J. Human factor risks
K. Estimated cost of alternative
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Facilities Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Prioritization Matrix
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Facilities Design
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
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Seven Mgt and Planning Tool
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
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Seven Mgt and Planning Tool
WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
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WINTER 2012 IE 368.FACILITY DESIGN AND OPERATIONS MANAGEMENT
Project Topics
Methods Lab Dela Cruz Group
Ergo Lab Dayo Group
ME Lab Cruz Group
Machine Shop Borja Group
CpE Lab Espaol Group
EE Lab Manas Group
ECE Lab Palma Group
Chairs Office Berbano Group
Deans Office including Board Room Alonzo Group
Faculty Room Almeyda Group
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