1. Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome/Opening Slide Welcome to Week 6 Discussion Experiment with New Format Attempt to Improve Course Productions “Talking Head” and Slides Visible Simultaneously – Videotape More Visual Stimuli, Size of Image(s) “Talking Head” (only) Video Produced on separate tape for VideoStreaming – Joined with Slides for Internet Delivery Same as Current

2. Slide 2 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Janitz) Mike Janitz – OSU-Tulsa

3. Slide 3 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Janitz) After working on the homework assignments I was wondering are there any software packages out there that can calculate a similarity coefficient or create a dendrogram? No free downloads (that I know of) Commercial Software that can be used: Microsoft Draw Visio Any CAD Package

4. Slide 4 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Janitz) I am having trouble understanding and applying the formulas to the homework questions. Do you have any examples that we can study to help explain the problems and their solutions? Can you elaborate?? Intercell Moves? Intracell Moves? Let’s use example on next slide 

5. Slide 5 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Janitz) Machines 1 5 6 7 2 3 4 M1 1 1 1 1 1 M2 1 1 1 1 M3 1 1 1 1 1 M4 1 1 1 M5 1 1 1

6. Slide 6 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Janitz) Looking at GT from a small job shop point of view, when do you realize your part/product variation is large enough to implement GT or cellular manufacturing? In other words, is GT only for large manufacturing companies with many products and families of products? I think it would be hard to justify GT and its support systems in a small company. GT as philosophy always applies. Exploit/Instill Similarities for Economy Limit -> Market Determined Survival Strategy – Small Company

7. Slide 7 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Janitz) On page 478 the author states “ To implement GT, formal classification and coding systems are incorporated into a computerized design retrieval system.” Is Singh trying to say that an information database (part descriptions and nomenclature) is not as good as coding and classifications (numbers)? Yes -- Difficult to parse/sort/search/match Variant prone – different spelling(s), name synonyms (e.g. tank) Efficiency – select vs. generate/type

8. Slide 8 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Janitz) Given that product variation and smaller batches are becoming more prevalent in today’s market, how can we, as engineering managers, determine or recognize when there is more product variation than your production equipment and engineering staff can keep up with? Clarification – Batch Size vs. Variation Production Order Size F (Set-up Cost, Demand Rate) Numbers of (Distinct) Products Composite Part vs. Custom Part All Features Optional vs. Groups

9. Slide 9 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Forth)

10. Slide 10 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Forth) How does one calculate the number of intercell moves as listed in Table 12.10 on page 498 of Singh? Move Down column, For each occupied position (each 1), note Cell Count Intercell Move, Count one for second and successive cells Machines 1 5 2 3 4 7 8 9 10 6 M1 1 1 1 1 1 1 1 1 1 M5 1 1 1 1 1 1 1 1 M2 1 1 1 1 1 M4 1 1 1 1 1 1 M3 1 1 1 1

11. Slide 11 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Forth) Could you please explain the intent of the following expression, which is taken from the text (Singh, page 498), "…three [moves] for parts 2,3 and 4 outside the cell but processed within the cell."? Parts 2, 3, 4 are each processed through M2 and M4 (in addition to those within Cell 1 Machines (M1/M5)) Thus, there are three additional machine to machine moves, within Cell 2 (Intracell)

12. Slide 12 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Forth) In the formula to calculate the decimal weighting for the ROC algorithm (Singh, page 491), what does the "b" factor represent? Could you please breakdown this formula as its factors are not clearly explained within the text? b is the entry (0,1) value (part doesn’t use machine/part uses machine) Rest of equation determines weights for row and column sorting -- (2 n, 2 n-1, … 2 2, 2 1,2 0 ) to get the “block diagonal.

13. Slide 13 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Ferguson) Keith “burning rubber”!!

14. Slide 14 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Ferguson) Are there equations for a circular layout or any other shapes other than the square, rectangle, and straight line? The formulas can generally be applied to any shape -- modify by using rectilinear travel (aisles) or other distance of travel – use centroid for machine group location

15. Slide 15 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Ferguson) How is cellular manufacturing affected by a JIT system? Kanbans control production and travel between cells (intracell), the (multi- machine) cell(s) is(are) usually dedicated to a single product until the kanban(s) are completed. Think of each cell as a single piece of production equipment.

16. Slide 16 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Ferguson) I know the book probably assumed negligible setup times in section 12.10.2, but is this a very good assumption to make? It’s generally not too bad – only affects solution if cells are close to capacity (not enough time for set-up) If concern, modify Eq. 12.23 to show a reduced capacity to allow for setup (iterate/apply sensitivity testing to LP) NOTE: Capacity = Ability to Absorb Variation

17. Slide 17 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Ferguson) About the mid-term --- What materials are going to be covered and will the suggested links and discussion sessions be included? Coverage Lectures 1-7, inclusive Discussion Sessions 2-7 (1999 and 2000, as noted) Instructor Suggested Links – Yes Browse Student Suggested Links

18. Slide 18 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Questions (Class) Other Questions as raised

19. Slide 19 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Discussion Session 6 End of Class Have a Good Week and I’ll see you next time!