11/13/2015 IENG 471 Facilities Planning 1 IENG Lecture 03 Product & Process Design

11/13/2015IENG 471 Facilities Planning 2 Agenda Assignments Product Design Parts Lists / Bills of Material (BOM) Part Drawings Product Structure Indented BOM Process Design Routing Sheets Operations Process Charts Data for Facilities Planning Design Questions & Issues

11/13/2015IENG 471 Facilities Planning 3 Product Design Must meet the needs of the customer QFD Must be communicated (internally) Product Drawings (Assembly, Detail) Parts List Part Structure Indented BOM covers both the parts list and part structure

11/13/2015IENG 471 Facilities Planning 4 Indented Bill of Materials A “BOM” is a document that: Lists all parts in an assembly Shows the quantity of all components Allows for the roll-up of costs Shows the sequence of assembly Each indentation shows the components of the sub-assembly

11/13/2015IENG 471 Facilities Planning 5 Example: Manual Juicer

11/13/2015IENG 471 Facilities Planning 6 Example: Manual Juicer

11/13/2015IENG 471 Facilities Planning 7 Example: Manual Juicer Function of the product: Obtain seed-free juice from produce Principle(s) of operation: Lever (Class 2) to provide pressure Grating to stop seeds Gravity to drain the juice

11/13/2015IENG 471 Facilities Planning 8 Example: Manual Juicer Materials of construction: Aluminum (sandcast) body Rubber feet Cost of the artifact: $ 0.32 in aluminum $ 0.04 in rubber $ ??? in labor, shipping, packaging, etc.

11/13/2015IENG 471 Facilities Planning 9 Indented BOM & Cost Roll-up: (1) Juicer Assembly$ 0.36 (1) Body Sub Assembly$ 0.18 (1) Body Casting$ 0.14 (4) Rubber Feet$ 0.01 (1) Strainer Casting$ 0.05 (1) Lever Casting$ 0.10 (1) Hinge Pin$ 0.03 Example: Manual Juicer

11/13/2015IENG 471 Facilities Planning 10 BOM Example in Excel QuantityDescriptionCost 1 Juicer Assembly $ Body Sub-Assembly. $ Body Casting.. $ Rubber Feet.. $ Strainer Casting. $ Lever Casting. $ Hinge Pin. $0.03.

11/13/2015IENG 471 Facilities Planning 11 Process Design Steps in Process Identification 1. Define elemental operations 2. Identify alternative process(es) for each operation 3. Analyze alternative processes for each operation 4. Standardize processes for each operation 5. Evaluate alternative processes for overall production 6. Select processes for overall production

11/13/2015IENG 471 Facilities Planning 12 Routing Example ROUTING PART NAME:Shaft, VisePREPARED BY: DATE: PART NUMBER: DRAWING NUMBER: GT CODE: MATERIAL:Brass LABOR RATE: TOTAL COST: Process Parameters Estimated Op.SpeedFeedDepthLaborSetup No.Operation Descriptionft/minrpmipripmin.Machinehrs.hrsCostRemarks 1Cut material from bar150 band saw0.10 Leave extra for machining 2Face 1st end of shaft lathe take minimal needed for cleanup 3Face 2nd end of shaft lathe cut to length per print 4Turn diameter to length, rough lathe leave.03 for finish cut 5Turn diameter to length, finish lathe0.10 6Cut groove lathe Chamfer end of shaft lathe Turn diameter to length, rough lathe leave.03 for finish cut 9Turn diameter to length, finish lathe Chamfer end of shaft lathe Center drill end of shaft lathe Drill hole in end lathe drill extra deep 13Tap hole lathe0.10 hand tap, lots of oil 14Center drill for cross hole mill Drill cross hole mill Chamfer cross hole mill0.05 both sides

11/13/2015IENG 471 Facilities Planning 13 Operation Process Chart Circles represent operations Number in circle represents standard operation Prefix in circle identifies: Subassemblies (SA) – child levels Assemblies (A) – parent level in this view Circles are annotated with operation description Boxes represent inspections Number in box represents standard operation Boxes are annotated with inspection description Arcs (lines) represent component(s) Arcs are annotated with part number & description for introduced components (See Figure 2.12 in text, p. 44)

11/13/2015IENG 471 Facilities Planning 14 Example: Manual Juicer Operations-Process Chart Body Casting 4001 Rubber Feet 4021 Strainer Casting 4002 Lever Casting 4003 Hinge Pin Trim, sand, inspect 0102 Trim, inspect 0101 Trim, sand, inspect 0101 Trim, sand, inspect 0101 Trim, sand, inspect A1 A2 Plastic Bag 4031 SA1 I1

11/13/2015IENG 471 Facilities Planning 15 Standard OPC Symbols

11/13/2015IENG 471 Facilities Planning 16 Process Design Result The result of the process design can be a precedence diagram: Take the OPC and turn it on its’ side. Connect the component arcs with a single operation (START), and you have a Precedence Diagram The precedence diagram can be converted to a PERT chart for SCHEDULE DESIGN

11/13/2015IENG 471 Facilities Planning 17 Example: Manual Juicer Precedence Diagram A1A SA1 I1 0100

18 PERT: Scheduling Terminology Activity - A specific task or set of tasks that are required by the project, use up resources, and take time to complete Event - The result of completing one or more activities. An identifiable end state occurring at a particular time. Events use no resources. Network - The combination of all activities and events define the project and the activity precedence relationships Meredith, J. R. & Mantel, S. J. (2006) 11/13/2015IENG 471 Facilities Planning

19 PERT: Scheduling Terminology Path - The series of connected activities (or intermediate events) between any two events in a network Critical - Activities, events, or paths which, if delayed, will delay the completion of the project. A project’s critical path is understood to mean that sequence of critical activities that connect the project’s start event to its finish event Meredith, J. R. & Mantel, S. J. (2006) 11/13/2015IENG 471 Facilities Planning

20 PERT: Activity-on-Node Network Fundamentals X Y Z Y and Z are preceded by X Y and Z can begin at the same time, if you wish (2) ABC A is preceded by nothing B is preceded by A C is preceded by B (1) J K L M J, K, & L can all begin at the same time, if you wish (they need not occur simultaneously) All (J, K, L) must be completed before M can begin but XZ AA Y (3) (4) Z is preceded by X and Y AA is preceded by X and Y Meredith, J. R. & Mantel, S. J. (2006) 11/13/2015IENG 471 Facilities Planning

21 PERT: Activity on Node Notation Early Start (ES)Early Finish (EF) Activity Duration (D) Late Start (LS)Late Finish (LF) 11/13/2015IENG 471 Facilities Planning

22 PERT: Calculating ES and EF Forward Pass Through Network: Move left to right, covering each simultaneous activity in order ES = maximum of EF for all immediate predecessor activities (0 for START activity) EF = ES + Duration Critical Time = EF of the END activity 11/13/2015IENG 471 Facilities Planning

23 PERT: Calculating LS and LF Backward Pass Through Network: Move right to left, covering each simultaneous activity in order LF = minimum of LS for all immediate successor activities (Critical Time for END activity) LS = LF – Duration Slack (Float) Time: LS – ES Note: Slack = 0 for Critical Activities 11/13/2015IENG 471 Facilities Planning

PERT: Critical Path Example 24 A 1 B 3 C 3 D 2 F 1 E 4 G 1 H 1Z Critical Time = 11 sec Critical Path = A, C, E, H, ZSlack B, F, G = 2 sec Slack D = 1 sec 11/13/2015IENG 471 Facilities Planning

25 PERT: Critical Path Management CP are those activities where ES = LS Any delay in these activities will delay production! Wrong to say that these activities are the most important, though: Frequently, activities with slack are put off until too late if not monitored! Other paths may be near-critical, and will also delay the project if not monitored! 11/13/2015IENG 471 Facilities Planning

11/13/2015IENG 471 Facilities Planning 26 Tying Critical Path to Facilities Critical Path is connected to Makespan If this were a repetitive operation environment: Makespan is the total time for a single, physical unit to go through all operations In manufacturing, the time difference between the start and finish of a sequence of jobs or tasks In health care, the duration of a patient’s medical experience for a treatment episode Team exercise Suppose that you had to schedule people to produce a product What would you do to operations on the CP? What might you do with non-CP operations? Skorin-Kapov, J. & A. J. Vakharia

11/13/2015IENG 471 Facilities Planning 27 Questions & Issues HW 2: Hands on assignment to develop: BOM Operations Process Chart Precedence Diagram Team exercise Teams must be different from Project Teams Semi-randomly assigned 4 people per team (5 people, if necessary) Other tools are in MIL Lab (IER 310) Leave the tools there, but OK to take the product parts