Factory Physics®? Perfection of means and confusion of goals seem to characterize our age. – Albert Einstein.

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Presentation transcript:

Factory Physics®? Perfection of means and confusion of goals seem to characterize our age. – Albert Einstein

What is Factory Physics®? Quantitative Tools: probability queueing models optimization Operations Management: inventory management shop floor control (MRP, JIT) scheduling, aggregate planning capacity management Manufacturing Principles: characterize fundamental logistical behavior facilitate better management by working with, instead of against, natural tendencies

Why Study Factory Physics®? Ideal: sophisticated technology Reality: blizzard of buzzwords gurus automation Lack of System JIT ERP information technology OPT TQM BPR control methods FMS MBO benchmarking

Can’t Rely on Benchmarking can result in an increasing gap in performance when standard is accelerating. Leader Follower

Need for a Science of Manufacturing Goals rationalize buzzwords recognize commonalties across environments accelerate learning curve Perspective basics intuition synthesis Practices change, but principles persist!

Scope of Factory Physics® Process Line System

Factory Physics® Definition: A manufacturing system is a network of processes through which parts flow and whose purpose is to generate profit now and in the future. Structure: Plant is made up of routings (lines), which in turn are made up of processes. Focus: Factory Physics® is concerned with the network and flows at the routing (line) level.

Product/Process Matrix Low Volume Low Standardization Multiple Products Low Volume Few Products Higher Volume High Volume High Standardization Void Jumbled Flow (job shop) Commercial Printer Disconnected Line Flow (batch) Heavy Equipment Customization Mass Connected Line Flow (assembly batch) Auto Assembly Void Continuous Flow Sugar Refinery

Conclusions Factory Physics® is: a set of manufacturing principles tools for identifying leverage in existing systems a framework for designing more effective new systems still being developed…