IE 1055 2025 Homework 4 Due Feb 1 2017 1 Submit your project topic 2 13 pts List and briefly describe what other items occupy space in a department besides machines operators and materials Answer 13 pts Kanban Bins if it is full it is considered material but when it is empty it still takes up space especially if there are multiple Kanban bins waiting to be refilled Raw materials storage Finished product storage Staging areas some products require staging areas before or after the part or material is processed Visual management boards Desks and work areas for computers that link to the Enterprise Resource Planning ERP system The desk area may also have work instructions statistical process control SPC data and other items Personnel space operators will need areas to store their coats purses etc while they are working Safety items departments may require safety items such as fire extinguishers sinks safety showers and first aid All of these items must be stored or placed for easy access Space for proper service systems such as gas lines ventilation power wires dust hogs oil tanks heating systems and power control panels Aisles for within department movement these are needed to allow workers to have enough space to be able to comfortably move through each department Material handling or transportation vehicles There may also be material handling carts or conveyors many departments have objects that are too heavy to carry so they have carts or conveyors to move the material around even from machine to machine Clearances around equipment to provide access for maintenance and repair Tools fixtures and jigs oftentimes products will require tools or jigs that need to be changed out THIS SOLUTION MAY ONLY BE USED FOR IE 1055 2025 SPRING 2017 3 13 pts 3 7 Answer 13 pts Pros Reduced travel distances Less congestion during peak delivery times Flexibility in the flows within the departments Simpler material handling equipment Cons Lower utilization Complexity of flow patterns May restrict expansion I O point allocation decisions need to be made for every part Require duplication of resources forklifts operators etc Considerations Resources available required Future expansion plans Optimize flow times Cost feasibility of extra I O points Utilization of each I O point Frequency Volume of material shipped received Storage space availability at each I O point Outside accessibility for trucks Delivery lot sizes Delivery shipment unit load sizes Required paper work and communications 4 17 pts Use the spatial schematic given in problem 3 14 but do not answer parts a to d that are given in the text rather consider a Find the flow path length for part 1 with routing A C E D F b Find the flow path length for part 2 with routing B F C D F c Let there be two more parts made in this facility part 3 with routing A E F D and part 4 with routing B E C E F Assuming that you only make parts 1 to 4 in this facility if you could change the locations of work areas A to F but had to keep them in a line how would you reorder them Justify your answer Assume that if you change the order of the work areas the distance from the first location to the second location remains the same 100 ft and similarly for the other locations For example if you choose to put C in the first position and D in the second position then the distance from C to D would be 100ft Is there further information that you would want to know prior to reordering departments A to F If so what is it THIS SOLUTION MAY ONLY BE USED FOR IE 1055 2025 SPRING 2017 Answer 17 pts a Find the flow path length for part 1 with routing A C E D F 175 100 25 50 350 b Find the flow path length for part 2 with routing B F C D F 200 125 75 50 450 c We show the from to flow density in the following table Since there is no volume data I have assumed the flow volume for each part is the same A A B C D E F B C 1 D 1 1 1 1 1 E 1 1 2 F 1 2 2 If the direction of flow is not considered the matrix is modified as on the right A A B C D E F B C 1 D 1 E 1 1 3 1 F 1 1 3 2 We will put C and E and D and F as close as possible because they have the highest flow density and put E and F close to each other This gives a partial potential solution of CEFD or DFEC This arrangement at the end of the line where the distances are shortest will minimize travel for locations moving the most units Assuming the number of each type of component being moved is the same ABCEFD AC 1 AE 1 BE 1 BF 1 CD 1 CE 3 CF 1 DE 1 DF 3 EF 2 175 1 250 1 150 1 175 1 125 1 75 3 100 1 50 1 25 3 25 2 1375 BACEFD AC 1 AE 1 BE 1 BF 1 CD 1 CE 3 CF 1 DE 1 DF 3 EF 2 75 1 150 1 250 1 275 1 125 1 75 3 100 1 50 1 25 3 25 2 1375 Then we have the following potential solutions ABCEFD and BACEFD A and B are interchangeable since they each have two movements to other locations A 1 C 1 E B 1 E 1 F THIS SOLUTION MAY ONLY BE USED FOR IE 1055 2025 SPRING 2017 If we don t consider the space requirements between areas Solution part 1 ACEDF needs to move 6 units part 2 BFCDF needs to move 8 units part 3 AEFD needs to move 5 units and part 4 needs to move 5 units The total is 24 move units Note we also need to know the relative volume in unit loads of the different components this can be incorporated into the from to charts above 5 13 pts Why has there been an increase in the use of visual management on many shop floors Answer 13 pts A visual management system can make a shop floor look better and help a department perform better By making things such as daily production output and quality very visible this helps workers to see how their actions directly affect these measures It also provides a good feedback mechanism for workers to know how well they are performing It also facilitates managing a work area because production output and quality information are clearly displayed Visibility is one of the methods by which the JIT philosophy is implemented Visibility may include charting daily production output compare to planned output quality kanbans used in a pull system colored standard containers etc The wider use of JIT and lean systems has lead to an increase in the use of visual management 6 2 28 30 pts …