ENG408 - Presentation 04
Transcript of ENG408 - Presentation 04
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,low Space and low Space and ctivity Relationships ctivity Relationships
I
epartmental Planningepartmental Planning
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,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
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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
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: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?
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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
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Supplier
Shipment without QC
Manufacturer
Qualitycontrol Defects
Supplier
Supplier
Shipment after QC
Manufacturer
Qualitycontrol Defects
Supplier
Manufacturing methodologies change Manufacturing methodologies change
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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
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Product layout (Flow shop)
Fixed product layout
Process layout (Job shop)
Group layout
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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
Combine all workstations required to produce the
product with the area
required for staging theproduct
Capable of being grouped into
families of similar parts
roup layout(product
)family layout
Combine all workstations required to produce the
family of products
None of the above rocess
epartment( )job shop
Combine identical
workstations intodepartments Combine similardepartments
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–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
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Group Technology – Cellular Group Technology – Cellular ManufacturingManufacturing
Group technology (product family) departmentsaggregate medium volume-variety parts into familiesbased on similar manufacturing operations anddesign attributes.
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–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
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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
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© Wiley 2007
Before GT
After GT
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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
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: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
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Group parts together so that
they can be processed as a
family Links parts and
machines in
-machine partmatrixMachine-part matrix
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Group parts together so that they can be
processed as afamily
Links parts and machines in -machine part matrix
Machine-part matrix
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.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
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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
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Direct clustering algorithmDirect clustering algorithm
5. Sort the columns (1 in the first row movesthe column to the left, then 1 in the secondrow, etc.)
2
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Direct clustering algorithmDirect clustering algorithm
6. Sort the rows (1 in the first column moves therow upward, then 1 in the second column, etc.)
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Direct clustering algorithmDirect clustering algorithm
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irect clustering algorithm irect clustering algorithm “ ”ottleneck machines“ ”ottleneck machines
Machine 2 which is needed for# #parts 3 and 5 creates
!conflicts
DCA
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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?
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4 2 3a 3b 1
Duplicated machine 2 Duplicated machine 3
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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
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Cl Id ifi iCl t Id tifi ti
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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
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Cl t Id tifi tiCl t Id tifi ti
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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
Cluster Identification Cluster IdentificationAlgorithmAlgorithm
Cl t Id tifi tiCl t Id tifi ti
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.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
Cluster Identification Cluster IdentificationAlgorithmAlgorithm
Cl t Id tifi tiCl t Id tifi ti
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.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
Cluster Identification Cluster IdentificationAlgorithmAlgorithm
Cl t Id tifi tiCluster Identification
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.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
Cluster Identification Cluster IdentificationAlgorithmAlgorithm
Cl t Id tifi tiCl t Id tifi ti
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.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
Cluster Identification Cluster IdentificationAlgorithmAlgorithm