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Product and Process Analysis

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Data required for developing good layouts

• Product Analysis

Types of products and specifications

Detail of components

Production volume

• Process Analysis

Material flow (patern, diagram, data)

Types of layout


Input Data and Activities • What data are critical to the facility plan?

• Categorizes the information as:

P – Product (what?)

Q – Quantity (how much?)

R – Routing (where?)

S – Support (with what?)

T – Timing (when?)


Input Data and Activities

• Tompkins, White, et. al., categorize it as:

Product Design – what is to be produced?

Process Design – how is it to be produced?

Schedule Design – when and how much?

Product

Schedule Process

Facility


PRODUCT ANALYSIS


“What kind of product should be made?”


Product Analysis


Specification a.Dimension, Weight, Material &

Drawing

b.Quality of product

c.Specific requirement

Volume Production quantity & variation

Part’s

Breakdown

a.Flow process.

b.Assembly process.

c.Processing time.

d.Machine, jig, tool and other.

Product Design

• Based on – Function

– Aesthetics

– Costs

– Materials

– Manufacturing Methods

• Key point – The product design MUST be finalized before

designing the facility. Otherwise a flexible facility is needed.

Driven by market

demand


Tools Used in Product Design

• Product/Part Drawings

2-D, 3-D visualization

• Exploded Assembly Diagrams


Part drawing


Tools Used in Process Design

A partial list (dependent on product and service):

• Process Flowcharts and Process Maps

• Make vs. Buy

• Parts Lists

• Bill of Materials

• Route Sheets

• Assembly Charts

• Operations Process Charts

• Precedence Diagrams


Process Flowcharts

Reserve Storage

Quality Assurance

Back to Vendor

UPS

Parcel Post

Next-Day UPS

Mono-gramming

Embroid-ering

Hemming

Gift Boxing

Receiving Active Bins

Picking Packing Shipping


Process Maps

Place order

Drink

Eat salad or soup

Eat dinner

Receives check

Gives payment to waiter

Collect change, leave tip

Fill in tip amount

Give order to waiter

Prepare dinner order

Prepare soup or salad order

Give order to waiter

Is order complete?

Give soup or salad order to chef

Give dinner order to chef

Get drinks for customer

Deliver salad or soup order to customer

Deliver dinner to customer

Deliver check to customer

Receive payment for meal

Cash or Credit?

Bring change to customer

Run credit card through

Return credit slip to customer

Collect tip

Y

N

Credit

Cash

Customer Waiter Salad Chef Dinner Chef


Make vs. Buy?

Can item be

purchased?

MAKE

Can we

make the

item?

BUY

Is it cheaper

for us to

make?

BUY

Is the capital

available?

MAKE

Yes

No

Yes Yes

No

No No

BUY

Yes


Parts List

• A listing of component parts.

Company: TW Inc. Prepared By: JSU

Product: Air Flow Regulator Date: 6/30/2003

Part No. Name Drwg. No. Qty/unit Material Size Make/Buy

1050 Pipe plug 4006 1 Steel 0.5" x 1.00" Buy

2200 Body 1003 1 Aluminum 2.75" x 2.5" x 1.5" Make

3250 Seat Ring 1005 1 Stainless Steel 2.97" x 0.87" Make

3251 O-Ring - 1 Rubber 0.75" diam. Buy

3252 Plunger 1007 1 Brass 0.812" x 0.715" Make

3253 Spring - 1 Steel 1.4" x 0.225" Buy

3254 Plunger Housing 1009 1 Aluminum 1.6" x 0.225" Make

3255 O-Ring - 1 Rubber 0.925" diam. Buy

4150 Plunger Retainer 1011 1 Aluminum 0.42" x 1.2" Make

4250 Lock Nut 4007 1 Aluminum 0.21" x 1.00" Buy

PARTS LIST


Bill of Materials • Many different types of “structured parts lists”

Company: TW Inc. Prepared By: JSU

Product: Air Flow Regulator Date: 6/30/2003

Level Part No. Name Drwg. No. Qty/unit Make/Buy

0 0021 Air Flow Regulator 0999 1 Make

1 1050 Pipe plug 4006 1 Buy

1 6023 Main assembly - 1 Make

2 4250 Lock Nut 4007 1 Buy

2 6022 Body Assembly - 1 Make

3 2200 Body 1003 1 Make

3 6021 Plunger Assembly - 1 Make

4 3250 Seat ring 1005 1 Make

4 3251 O-Ring - 1 Buy

4 3252 Plunger 1007 1 Make

4 3253 Spring - 1 Buy

4 3254 Plunger Housing 1009 1 Make

4 3255 O-ring - 1 Buy

4 4150 Plunger retainer 1011 1 Make

BILL OF MATERIALS


Bill of Materials

12 Computer Device

11 Keyboard Assembly (Purchased)

10 Color Video Display Device

8 Video Panel (Purchased)

7 Circuit Board

9 Main CPU Unit

6 Power Supply Kit (Purchased)

5 PC Board Assembly

3 Main PC Board (Purchased)

4 Disk Drive Unit

2 Floppy Drive

1 Hard Drive


Route Sheet

Oper.

No.

Operation

Description

Machine

Type

Tooling Setup

(hr.)

Oper.

Time

(hr.)

Mtls.

Parts

0104 Shape, drill,

cut off

Auto sc.

Machine

.5 in dia coller, cir.

Form tool, .45”

diam center drill

5 0.0057 Alum

1”x12’

0204 Machine Slot

and thread

Chucker 0.045” slot saw,

turret slot

2.25 0.0067

0304 Drill 8 holes Auto dr.

unit

0.078” diam twist

drill

1.25 0.0038

0404 Debur and

Blow out

Drill press Deburring tool with

pilot

0.5 0.0031

SA 1 Enclose

subassembly

Dennison

hydraulic

press

None 0.25 0.0100

Company: ARC Inc.

Produce: Air Flow Regulator

Part: Plunger Housing

Part No. 3254

Prepared by: JSU

Part No. 6/6/03


Routing sheet MASTER ROUTING LIST MASTER ROUTING LIST

--PART NUMBER-- ---------DESCRIPTION---------- DATE ALT CODE BUYER/PLANNER --PART NUMBER-- ---------DESCRIPTION---------- DATE ALT CODE BUYER/PLANNER

DRAWING REVISIONDRAWING REVISION

H6709 HANDLE,DENSPLY PROBE 6/25/92 B 239 H6709 HANDLE,DENSPLY PROBE 6/25/92 B 239

G G

--------STANDARD-------- --------STANDARD--------

TIME MOVETIME MOVE

OPER WORK OPER SETUP CREW MACH --TOOLING REF-- --SETUP- -LABOR- -MACHINE-- I/O OPER WORK OPER SETUP CREW MACH --TOOLING REF-- --SETUP- -LABOR- -MACHINE-- I/O

BASIS TIME -----EFFECTIVE----BASIS TIME -----EFFECTIVE----

& ALT CENTER CODE CODE FACTOR GROUP NUMBER HOURS HOURS HOURS & ALT CENTER CODE CODE FACTOR GROUP NUMBER HOURS HOURS HOURS

CDE/-QTY- -DAYS- FROM TOCDE/-QTY- -DAYS- FROM TO

10 01226 1.0 01226 T9330 12.000 336.880 336.880 4 10 01226 1.0 01226 T9330 12.000 336.880 336.880 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99

PARTIAL AHEAD QTYPARTIAL AHEAD QTY

----------ROUTING DESCRIPTIONS---------- ----------ROUTING DESCRIPTIONS----------

MAKE @ AUTO 804843P MAKE @ AUTO 804843P

C 804843P B C 804843P B

A A02247 A A A02247 A

15 02053 1.0 02053 T9712 1.500 41.670 83.330 4 15 02053 1.0 02053 T9712 1.500 41.670 83.330 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99



DRILL & TAP 804843P1 DRILL & TAP 804843P1

B 804843P1 A B 804843P1 A

20 02053 1.0 02053 T9713 1.500 8.330 16.670 4 20 02053 1.0 02053 T9713 1.500 8.330 16.670 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99



KNURL OD KNURL OD

30 03029 1.0 .000 33.330 33.330 4 30 03029 1.0 .000 33.330 33.330 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99



SCOTCHBRITE/BELT SCOTCHBRITE/BELT

40 03105 1.0 03105 .000 3.000 3.000 4 40 03105 1.0 03105 .000 3.000 3.000 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99



PASSIVATE PASSIVATE

50 03005 1.0 .000 54.170 54.170 4 50 03005 1.0 .000 54.170 54.170 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99



BUFF BUFF

60 03007 1.0 03007 .000 50.000 50.000 4 60 03007 1.0 03007 .000 50.000 50.000 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99



GLASSBEAD KNURL/ SHIP GLASSBEAD KNURL/ SHIP


Analog model of the assembly process.

• Circles denote components

• Links denote

operations/subassemblies

• Squares represent inspections

operation

• Begin with the original product and

to trace the product disassembly

back to its basic components.

Assembly Chart 2200

3254

3253

3252

3251

3250

3255

4150

4250

A-1

Pack

SA-1

A-2

A-3

I-1 1050

A-4


Found by superimposing

the route sheets and the

assembly chart, a chart

results that gives an

overview of the flow within

the facility.

Operations Process Chart www.aeunike.lecture.ub.ac.id

Operator-Machine Charts • Tool for showing activity of

both operator and machine along a time line

• Also called “multiple activity chart”

Example: 1 minute to load

1 minute to unload

6 minute run cycle

0.5 minute to inspect and pack

0.5 minute to travel to another machine

Time Operator M1

0.5 U1 UNLOAD

1 U1 UNLOAD

1.5 L1 LOAD

2 L1 LOAD

2.5 I&P RUN

3 RUN

3.5 RUN

4 RUN

4.5 RUN

5 RUN

5.5 IDLE RUN

6 RUN

6.5 RUN

7 RUN

7.5 RUN

8 RUN

Cycle Time 8 min

Oper Idle 5.5 min

Mach. Idle 0 min

Prod. Rate 0.125 pc/min

ONE MACHINE


Operator Machine Charts

Time Operator M1 M2 Time Operator M1 M2 M2

0.5 U1 UNLOAD RUN 0.5 U1 UNLOAD RUN RUN

1 U1 UNLOAD RUN 1 U1 UNLOAD RUN RUN

1.5 L1 LOAD RUN 1.5 L1 LOAD RUN RUN

2 L1 LOAD RUN 2 L1 LOAD RUN RUN

2.5 I&P RUN RUN 2.5 I&P 1 RUN IDLE RUN

3 T-2 RUN RUN 3 T-2 RUN IDLE RUN

3.5 U2 RUN UNLOAD 3.5 U2 RUN UNLOAD RUN

4 U2 RUN UNLOAD 4 U2 RUN UNLOAD RUN

4.5 L2 RUN LOAD 4.5 L2 RUN LOAD RUN

5 L2 RUN LOAD 5 L2 RUN LOAD RUN

5.5 I&P RUN RUN 5.5 I&P 2 RUN RUN IDLE

6 T-1 RUN RUN 6 T-3 RUN RUN IDLE

6.5 RUN RUN 6.5 U3 RUN RUN UNLOAD

7 RUN RUN 7 U3 RUN RUN UNLOAD

7.5 IDLE RUN RUN 7.5 L3 RUN RUN LOAD

8 RUN RUN 8 L3 RUN RUN LOAD

8.5 I&P 3 IDLE RUN RUN

Cycle Time 8 min 9 T-3 IDLE RUN RUN

Oper. Idle 2 min

Mach Idle 0 min Cycle Time 9 min

Prod Rate 0.25 pc/min Oper. Idle 0 min

Mach Idle 1 min

Prod Rate 0.333333 pc/min

TWO MACHINES THREE MACHINES


PROCESS ANALYSIS


Manufacturing Process: Simple Description


Inventory

Suppliers$ $$

Material

Manufacturing Manufacturing

Manufacturing Inventory

Quality Assurance

Distribution

CACAT

RECYCLE

RECYCLE

CACAT

CACAT

RECYCLECACAT

WIP Stotage WIP Stotage WIP Stotage

Data requirement for layout decisions

• Frequency of flow of material / some other measure of interaction between departments

• Shape and size of departments

• Floor space available

• Location restrictions for departments, if any

• Adjacency requirements between pairs of departments, if any


Flow pattern at 800-acre Nissan plant in Smyrna, TN


Possible flow patterns


Dendrite flow pattern


Spine flow pattern


Five types of layout

• Product layout

• Process layout

• Fixed-position layout

• Group-technology layout

• Hybrid layout


Types of Departments/Layouts Volume

High

Medium

Low

Low Medium High Variety

Product

Department

Fixed Materials

Location

Department

Process

Department

Product

Family

Department

Product

Layout

Fixed Location

Layout

Group Technology

Layout

Process

Layout

Source: John S. Usher class notes www.aeunike.lecture.ub.ac.id

Product layout


Product Layouts

L

L

L L

L M

M

M

D D

D

D G

G

G

G A

A

Product C Department

Product A Department

P

P

P

Product B Department

A

Sh

ipp

ing

De

pa

rtme

nt

Re

ceiv

ing

De

pa

rtme

nt


Process layout

TM

TM TM

TM

DM

DM

DM

VMM VMM BM BM


The Process Layout

L

L

L

L

L

L

L

L

L

L M

M

M

M

D

D

D

D

D

D

D

D

G

G

G

G

G

G

A A A Receiving and Shipping Assembly

Painting Department

Lathe Department Milling

Department Drilling Department

Grinding Department

P

P


Flow of Materials in Process Layouts

L

L

L

L

L

L

L

L

L

L M

M

M

M

D

D

D

D

D

D

D

D

G

G

G

G

G

G

A A A Receiving and Shipping Assembly

Painting Department

Lathe Department Milling

Department Drilling Department

Grinding Department

P

P

Source: Russell & Taylor, 2007 www.aeunike.lecture.ub.ac.id

Group technology layout

TM

TM

TM

TM

DM

DM

DM

VMM

VMM

BM BM


Product Family (Cellular) Layout

L

L

L

L

L

L

L

L

L M

M

M

M

D D

D D

D

D

D

G

G

G G

G

G

A A

Receiving and Shipping

Special Department

Rotational Parts Cell

P

P

Rectangular Parts Cell


A Manufacturing Cell

Key: S = Saw L = Lathe HM = Horizontal milling machine VM = Vertical milling machine G = Grinder

Paths of three workers moving within cell Material movement

In Out Worker 1

Worker 2

Worker 3

Dir

ect

ion

of

pa

rt m

ov

em

en

t w

ith

in c

ell

S

L

HM

VM

G

VM

L

Final inspection

Finished part


Project (Fixed-Position) Layout

L

L

L

L

M

D D D

G

G G

G

A

A

Receiving and Shipping

P

Sto

rag

e

Sto

rag

e


Hybrid layout

TM

TM TM

TM

DM

VMM BM


Hybrid Layouts

• Combination of the layouts discussed. • A combination of group layout in manufacturing cells,

product layout in assembly area, and process layout in the general machining and finishing section is used.

TM

TM TM

TM TM DM

BM


General Characteristics

Characteristic Product Process Product

Family Project

Throughput Time Low High Low Medium

Work in process Low High Low Medium

Skill Level Choice High Med-High Mixed

Product Flexibility Low High Med-High High

Demand Flexibility Medium High Medium Medium

Mach Utilization High Med-Low Medium-High Medium

Worker Utilization High High High Medium

Reliability Can be

low

High High Medium

Unit production

cost

Low High Low High


Exercise – What Type of Layout?

• Ford Louisville Assembly Plant ___________

• Suburban Hospital ___________

• Louisville International Airport ___________

• KFC Restaurant ___________

• Boeing Aircraft ___________


Automated Manufacturing Cell


Flexible Manufacturing Systems Automated machining operations, tool changers

Automated material handling, computer control

Designed around size of parts processed & average processing time for parts

Can process wide variety of items quickly

Very few large systems exist

• Progressive layout – all parts same route

• Closed loop – larger variety, alternative routes

• Ladder layout – two machines work on same part

• Open field layout – most complex


Flow process chart

FLOW PROCESS CHART

Subject Charted TB03100 Face Panel Chart No. 112XAG

Drawing No. Part No. Chart of Method Present

Chart Begins Receiving Charted By N.L.

Chart Ends Steel Dept. Date Feb. 5/90 Sheet 1 of 1

Dist.

(ft)

Time Chart

Symbol

Oper

ID

Dept

ID

M/C

ID

# of

pieces

How

moved

Process Description

.02 1 A1 S&R 100 Truck Received material 0.022 wcs (51" x 102")

220 .02 1 H2 MF1 100 Forklift To crane bay area

2 WIP1 100 Stored temporarily

20 .02 2 H2 MF1 100 Conveyor To hydra shear

.01 1 M1 MF1 HS1 100 Cut to length (front panel)

50 .02 3 H3 MF2 13G

142

95 Forklift To machine #13G (100 ton press) or Komatsu

(machine 142) or to HYMAC 101 (7" & over neck)

.01 2 M2 MF2 101 95 Necking operation (punch hole)

160 .03 4 H3 MF2 95 Forklift To machine # 136

.03 3 M2 MF2 136 95 Punch holes

240 .01 5 H1 MF3 95 Forklift To machine #155 or machine #104 or machine #111

.05 4 M2 MF3 155 95 Braking operation

260 .01 6 H1 WIP2 94 AGV To marshalling area

3 S&R 94 Temporary storage

150 .01 7 H3 WIP3 94 AGV To steel dept.

Summary

Event Total Time Distance

Operations 4

Inspections — — —

Transportations 8 (min.) 1100 ft.

Storages 3

Delays


Simbol-Simbol ASME


Flow diagram


MESIN FRAIS MESIN BUBUT

MESIN BORMESIN BOR

MEJA

PE

NE

RIM

AA

NP

EN

YIM

PA

NA

N

AL

AT

ME

JA

PE

RA

KIT

AN

Peluncur

Bahan

Peluncur

Bahan

PEMANGGANG

PA

INT

ING

PE

NG

EM

AS

AN

Peluncur

Bahan

Peluncur

Bahan

Peluncur

Bahan

Peluncur

Bahan

Peluncur

Bahan

Peluncur

Bahan

Peluncur

Bahan

1

1

2

2

1

3

MEJA

3

3

2

5

4

6

3

65

7

6

8

4

9

5

11

7

12

8

13

6

14

9

15

7

10

16 1

7

11

18

8

18

12

20

13

PE

NG

IRIM

AN

FINISHINGASSEMBLING

GU

DA

NG

DIAGRAM ALIR (FLOW DIAGRAM)

Qualitative flow data

• Relationship chart – A absolutely necessary – E especially important – I important – O ordinary – U unimportant – X undesirable

• Percentages of A, E, I, O, U and X ratings – A 2-5% – E 3-10% – I 5-15% – O 10-25% – U 25-60% – X depends


Qualitative flow data

• Color coding relationships

– A Red

– E Orange or Yellow

– I Green

– O Blue

– U Uncolored

– X Brown


Sample relationship chart

1. Form

2. Trim

3. Treat

4. Assembly

5. Pack and Ship

A/1

E/2

X/3

O/2

U

I/2

U

E/2

U

U

Code Reason

1 Bulky material

2 Ease of supervision

3 Safety


Quantitative flow data

• From-to frequency of trips matrix

Dept1

Dept2

Dept3

Dept4

Dept5

Det 6

Dept 1 - 12 3 3

Dept 2 21 -

Dept 3 4 5 - 8 8 8

Dept 4 - 4 4

Dept 5 1 2 2 15 - 19

Dept 6 4 9 7 19 -


Quantitative flow data

• Frequency of trips between departments matrix

Dept1

Dept2

Dept3

Dept4

Dept5

Dept6

Dept 1 - 33 7 3 1 4

Dept 2 33 - 5 2 9

Dept 3 7 5 - 8 10 8

Dept 4 3 8 - 19 11

Dept 5 1 2 10 19 - 38

Dept 6 4 9 8 11 38 -


Distance Measures

• Euclidean

• Squared Euclidean

• Rectilinear

• Tchebychev

• Aisle distance

• Adjacency

• Shortest Path


Euclidean, Squared Euclidean, Rectilinear and Tchebychev

Facility i

Facility j

(xj,yj)

(xi,yi)

|yi-yj|

|xi-xj|


Aisle Distance, Adjacency and Shortest Path

Facility i

Facility j

d

a

Facility k

b


HW for Gravity Method

• Two high-speed copiers are to be located in the fifth floor of an office complex that houses four departments of the Social Security Administration. Coordinates of the centroid of each department as well as the average number of trips made per day between each department and the copiers’ yet-to-be-determined location are known and given in Table below. Assume that travel originates and ends at the centroid of each department. Determine the optimal location-the x and y coordinates-for the copiers.


Dept. No. x Coordinate y Coordinate Average No. of Daily Trips to Copiers

1 10 2 6

2 10 10 10

3 8 6 8

4 12 5 4

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