IENG 471 Facilities Planning Schedule Design 12/29/2018 IENG 471 - Lecture 04 Schedule Design 12/29/2018 IENG 471 Facilities Planning (c) 2005-2009 D.H. Jensen

IENG 471 Facilities Planning Agenda Assignments Schedule Design Required Data Estimating Production Volume Estimating Equipment Needs (Equip. Frac.) Facilities Project Management Tools Questions & Issues 12/29/2018 IENG 471 Facilities Planning

IENG 471 Facilities Planning Assignments Current Assignment: HW: (HW 2) Product BOM Product Operation Process Chart Product Precedence Diagram Next Assignment: HW: (HW 3) See Assignment Link required input for each of the workstations equipment necessary for each machine steady state cycle time for each machine ideal machine assignment for each machine compute the idle time unit cost at each workstation total cost per good unit square footage for each workstation and the total space required 12/29/2018 IENG 471 Facilities Planning

Schedule Design Overview Schedule Design is undertaken to decide for a facility design: How much should the facility be designed to produce When should the facility be able to produce the product 12/29/2018 IENG 471 Facilities Planning

Impacts of the Schedule Design: The Schedule Design of the facility will impact: Types of machines required Processing equipment Storage equipment Material handling equipment Number of machines required Number of employees required Space requirements For all of the above, plus support functions (services, utilities, …) 12/29/2018 IENG 471 Facilities Planning

Information Req’d: Marketing What products are to be produced What volume of each product is expected to be produced (and when) How probable are the production requirements Seasonality and life cycle considerations Where are the products to be acquired Who will acquire the products What are the product development plans 12/29/2018 IENG 471 Facilities Planning

IENG 471 Facilities Planning 12/29/2018 Production Volume Types of Manufacturing Systems: Job Shop Batch/Cellular Mass Production Approximate Annual Volume: Kalpakjian Type of Production No. Produced Typical Products Prototype 1 - 10 Anything Piece/Small Batch 10 - 5,000 Aircraft, Machinery, Dies Batch/High Volume 5,000 - 100,000 Trucks, Ag. Equip., Engines Mass Production Over 100,000 Cars, Appliances, Fasteners Three typical manufacturing strategies. Compared by volume (first two are specific types of Job Shop) Job Shop 12/29/2018 IENG 471 Facilities Planning (c) 2005-2009 D.H. Jensen

IENG 471 Facilities Planning 12/29/2018 Characteristics Type of Production System Job Shop Batch Prod. Mass Prod. General Equipment Special Production Rate Production Quantity Process Plant Layout Flow Line Labor Skill Part Variety Kalpakjian Other characteristics of the three types of Production Systems. 12/29/2018 IENG 471 Facilities Planning (c) 2005-2009 D.H. Jensen

Example Job Shop Layout Drill V. Mill Lathe L. Paint Oven H. Mill P. Paint Grind CMM Receiving Shipping 12/29/2018 IENG 471 Facilities Planning

Example Mass Production Layout V. Mill H. Mill Drill Grind Drill CMM Lathe L. Paint Receiving Oven Shipping 12/29/2018 IENG 471 Facilities Planning

Example Batch/Cell Production Layout V. Mill Grind Drill Grind Drill H. Mill Drill CMM Lathe L. Paint Receiving Oven Shipping 12/29/2018 IENG 471 Facilities Planning

Volume, Variety & Automation IENG 471 Facilities Planning 12/29/2018 Volume, Variety & Automation Rembold, et. al. Transfer Line 100,000 10,000 1,000 100 1 Production Quantity High Medium Low Increasing Flexibility Batch Flow Line Increasing Productivity Based on quantity to produce and the variety demanded, different strategies for mfg can be employed. Left, top is typical mass production equipment. Lower, right is typical job shop equipment (if automated). Middle ranges are typical of Batch Production. Flexible Mfg Sys Mfg Cell NC Machine 1 10 100 1,000 Low Medium High Part Variety 12/29/2018 IENG 471 Facilities Planning (c) 2005-2009 D.H. Jensen

Which Type to Use?: Pareto Chart 80% of any problem is the result of 20% of the potential causes* Histogram categories are sorted by the magnitude of the bar A line graph is overlaid, and depicts the cumulative proportion of products Quickly identifies where to focus efforts Pareto Chart for Product Volume 20 40 60 80 100 120 Prod A Prod B Prod C Prod D Prod E Prod F Prod G Prod H Product Type Est. Volume Req’d 0% 20% 40% 60% 80% 100% 120% Cumulative % 12/29/2018 IENG 471 Facilities Planning

Estimating Production Volume with Scrap The production facility must operate in the “real world” In the real world, things go wrong – defects! To size the facility, the plant capacity must include extra volume for scrap: At a single workstation (k) the formula is: where: Ik is the input amount required for the process to achieve goals Ok is the output amount required of the process, and Pk is the percentage of scrap generated by the process per unit 12/29/2018 IENG 471 Facilities Planning

Estimating Production Volume with Scrap IENG 471 Facilities Planning 12/29/2018 Estimating Production Volume with Scrap Most processes are a sequence of operations We need to know the sequence and individual scrap rates of each of the operations… Good thing we got those Operation Process Charts! Assuming that each unit must go through each operation in a chain of operations, the plant capacity must include extra scrap volume: At end of a single chain of (n) individual operations, the formula for total input volume required is: where: On is the output amount required at the end of the operation chain, and Pk is the percentage of scrap per unit generated by the kth operation, starting with operation 1 and continuing through operation n 12/29/2018 IENG 471 Facilities Planning (c) 2005-2009 D.H. Jensen

Example 1: Express Input 1 as a function of the Quota O1=I2 O2=I3 O3=I4 O4=Q 1 2 3 4 P1=2% P2=5% P3=1% P4=0.5% 12/29/2018 IENG 471 Facilities Planning

Example 2: Express Input 1 as a function of the Quota O1=I2 O2+OR=I3 O3=I4 O4=Q 1 2 3 4 OR P1=2% P2=5% IR P3=1% P4=0.5% R PR=1% 12/29/2018 IENG 471 Facilities Planning

IENG 471 Facilities Planning Example 3: Express Input 1 as a function of the Quota I1 O1+OR=I2 O2=I3 O3=I4 O4=Q 1 2 3 4 OR P1=2% IR P2=5% P3=1% P4=0.5% R PR=1% 12/29/2018 IENG 471 Facilities Planning

Example 4: Find Input 1 and the system Total Scrap Cost O1=I2 O2=I3 Q=1000 1 2 3 P1=3% S1=$5 P2=5% S2=$10 P3=7% S3=$15 12/29/2018 IENG 471 Facilities Planning

IENG 471 Facilities Planning Example 5: Find Input 1 and the system Total Scrap Cost (Note: Proportion scrap reversed from Example 4) I1 O1=I2 O2=I3 Q=1000 1 2 3 P1=7% S1=$5 P2=5% S2=$10 P3=3% S3=$15 12/29/2018 IENG 471 Facilities Planning