OPMT 303 1st Edition Lecture 4 Outline of Last Lecture 1 Reasons for Products and service design 2 Major Functions of Strategy Design 3 Product Design 4 Service Design Outline of Current Lecture 1 Process selection and facility layout 2 Characteristics of various processes 3 Layouts 4 Product Layout Objectives 5 Steps to Design an Assembly Line 6 Mass Customizations 7 Strategic capacity planning for products and services Current Lecture I Process selection and facility layout a Process selection deciding on the way production of goods or services will be organized i Occurs when new products or services being planned ii Also occurs due to technological changes in products and equipment b Forecast product and service design technological influence process selection c It effects facilities and equipment layout and work design II Characteristics of various processes a Job Shop i Used in low volume and high variety goods services ii High variety of product iii High flexibility with general purpose equipment and skilled workers These notes represent a detailed interpretation of the professor s lecture GradeBuddy is best used as a supplement to your own notes not as a substitute III iv Random jumbled product flow b Batch i Used in moderate volume of goods or services ii A moderate degree in variety of products iii Equipment not as flexible as job shop but still is intermittent iv Dominant product flow c Repetitive i Higher volume of standardized goods or services ii Special equipment with low skill work iii Dominant production flow iv Low variety of products with modifications d Continuous i High volume of nondiscrete highly standardized output ii Standard variety of product iii Dominant production flow iv Special equipment with high or low skilled work e Project i Used for non routine work for unique set of objectives to do in a limited time ii One product being offered iii Equipment can be flexible or not iv Skills range from low to high Layouts a Configuration of departments work centers equipment and people with particular emphasis on movement of work customers or materials through the system b Four different types of layouts i Process layout arrangement of people and equipment according to the similarity of jobs performed 1 Maintenance cost lower because equipment less specialized 2 Requires frequent adjustments 3 Can handle a variety of processing requirement ii Product layout arrangement of people and equipment according to the sequence of operations which are performed on the product 1 Production line standardized layout arrangement according to a fixed sequence of production tasks 2 Assembly line standardized layout arranged according to a fixed sequence of assembly tasks 3 Achieve a high degree of labor and equipment utilization 4 Preventive maintenance periodic inspection and replacement of worn parts or those with high failure rates iii Fixed position layout people and equipment are brought to site of a project construction 1 Used in large construction projects ship building and production of large aircraft and space mission rockets 2 Attention focused on timing of material and equipment deliveries 3 Also used in farming firefighting road building home building remodeling and drilling for oil IV V VI iv Group Technology layout grouping together of parts or products into families by processing operations so that all members of the family are processed in a miniature factory called GT cell 1 Items grouped by size shape and function 2 Three methods for accomplishment a Visual inspection b Examination of design c Production flow analysis Product Layout Objectives a Minimize number of station i Minimize workforce ii Minimize handling cost b Balance assembly line i Each station should be assigned an equal amount of work ii Cycle time time interval between completing two successive units 1 Maximum time allowed to complete all tasks at each station Steps to design an Assembly Line a First draw a precedence diagram b Next calculate the cycle time i C operating time desired output rate c Lastly balance the line i Choose the task with the greatest number of followers ii Break a tie by choosing a task with the longest completion time d Two rules to always follow i Always preserve the sequence of operations ii Do not ever exceed the cycle time e Evaluation of the Solution i Number of station the same as the theoretical minimum number of stations ii There is not an equal amount of work going on at each station iii Line efficiency total number of tasks no of stations cycle time iv Balance delay percentage of idle time of a line 1 100 line efficiency balance delay 2 95 average line efficiency in US Mass Customization a CIM i Computer integrated manufacturing to link various parts of an organization to achieve rapid response to customer orders and or product changes ii Integrates information from other areas of an organization with manufacturing iii CAD 1 Computer Aided Design computer software to create or modify an engineering design including geometric modeling stress and strain analysis and simulation of part movement drafting and storing specifications 2 Major benefit of CAD is the increased productivity of designers iv CAM 1 Computer Aided Manufacturing linking NC numerically controlled machines CNC computerized numerical control and robotics to monitor production process coordinate flow of materials between machines and routing or rerouting jobs a NC machines programmed to follow a set of processing instructions based on mathematical relationships that tell the machine the details of the operation being performed b CNC individual machines have their own computer b FMS VII i Flexible manufacturing system includes a number of work stations an automated material handling system and system supervisory computer control to decrease the tome to change tools and fixtures load and unload machines and move materials to and from manufacturing cells 1 Automated storage retrieval system automated guided vehicles c CAPP i Computer Aided Process Planning plans machining operations and determines routing between machines 1 Robotics 2 CAD 3 CAM d Cellular Manufacturing i Manufacturing call included the machines and tools necessary to efficiently produce a family of parts e GT i Group technology a process of coding and classifying families of parts according to similarities in their geometric characteristics or in their material or manufacturing requirements Strategic Capacity Planning for Products