Backward Analysis, Route Sheet, MPPC

Operation Description Route Sheet Company: ARC Inc. Produce: Air Flow Regulator Part: Plunger Housing Part No. 3254 Prepared by: JSU Part No. 6/6/03 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

Routing sheet

Analog model of the assembly process. 2200 Assembly Chart 3254 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. 3253 3252 3251 SA-1 A-1 3250 3255 A-2 4150 4250 A-3 I-1 1050 A-4 Pack

Production Requirements – Yield Loss Pi – Production input to operation i si – Fraction of Pi lost (scrap) Oi – output of process i Pi i Oi Pisi

Production Requirements – Series Systems 1 2 . . . P1 n On P1s1 P2s2 Pnsn

Example 5 processes in series Need 2000 units out

Production Requirements – Non Series Part A Part B Work backward from end of the line. M1 s1=1% 1 M2 s3=2% 3 M2 2 s2=2% M3 s4=1% 4 M4 s5=4% 5 100,000 units

Distance Measures Euclidean Squared Euclidean Rectilinear Tchebychev Aisle distance Adjacency Shortest Path

Euclidean, Squared Euclidean, Rectilinear and Tchebychev

Aisle Distance, Adjacency and Shortest Path

Layout evaluation criteria cij cost of moving a unit load of material unit distance between departments i and j fij number of loads or trips required between departments i and j dij distance between departments i and j