product, process and schedule design - universitas product designers types of products and...

Product, Process and Schedule Design

www.aeunike.lecture.ub.ac.id

Among the questions to be answered before alternative facility plans can be generated are the following:

1. What is to be produced? 2. How are the products to

be produced? 3. When are the products

to be produced? 4. How much of each

product will be produced?

5. For how long will the products be produced?

6. Where are the products to be produced?

Product, process, and schedule design

Facilities location / schedule design


Input Data and Activities

• Tompkins, White, et. al., categorize it as:

Product Design – what is to be produced?

Process Design – how is it to be produced?

Schedule Design – when and how much?

Product

Schedule Process

Facility


• Product designers Types of products and specifications (dimensions)

Detail of components, material composition

Packaging

• Process planner Required processes identification

Required processes sequence

• Schedule designers / production planner Production quantities

Production equipment schedules

• FACILITIES PLANNER Is dependent on timely and accurate input from product, process, and schedule designers to work effectively


PRODUCT DESIGN


“What kind of product should be made?”


Product Analysis


Specification a.Dimension, Weight, Material &

Drawing

b.Quality of product

c.Specific requirement

Volume Production quantity & variation

Part’s

Breakdown

a.Flow process.

b.Assembly process.

c.Processing time.

d.Machine, jig, tool and other.

Product Design

• Based on – Function – Aesthetics – Costs – Materials – Manufacturing Methods

• QFD • Benchmarking

• Key point

– The product design MUST be finalized before designing the facility. Otherwise a flexible facility is needed.

Driven by market

demand


Tools Used in Product Design • Product/Part Drawings

2-D, 3-D visualization

• Exploded Assembly Diagrams


Tools: • CAD (computer aided design) • CE (concurent engineering), to improve relationship between component/product and its cost

Part drawing


PROCESS DESIGN


Process Planner

• Responsibilities:

– HOW the product is to be produced

– WHO should do the processing

– HOW the part will be produced

– WHICH equipment will be used

– HOW LONG it will take to perform the operation


Tools Used in Process Design • Identifying Required Processes:

– Make vs. Buy

– Parts Lists

– Bill of Materials

• Selecting the Required Processes: – Input: process identification

– Tool: CAPP (computer aided process planning)

– Output: Route Sheets

Process Identification

Define elemental operations Step 1

Identify alternative process for each operation Step 2

Analyze alternative processes Step 3

Standardize processes Step 4

Evaluate alternative processes Step 5

Select processes Step 6

Make vs. Buy?

Can item be

purchased?

MAKE

Can we

make the

item?

BUY

Is it cheaper

for us to

make?

BUY

Is the capital

available?

MAKE

Yes

No

Yes Yes

No

No No

BUY

Yes


Parts List

• A listing of component parts.

Company: TW Inc. Prepared By: JSU

Product: Air Flow Regulator Date: 6/30/2003

Part No. Name Drwg. No. Qty/unit Material Size Make/Buy

1050 Pipe plug 4006 1 Steel 0.5" x 1.00" Buy

2200 Body 1003 1 Aluminum 2.75" x 2.5" x 1.5" Make

3250 Seat Ring 1005 1 Stainless Steel 2.97" x 0.87" Make

3251 O-Ring - 1 Rubber 0.75" diam. Buy

3252 Plunger 1007 1 Brass 0.812" x 0.715" Make

3253 Spring - 1 Steel 1.4" x 0.225" Buy

3254 Plunger Housing 1009 1 Aluminum 1.6" x 0.225" Make

3255 O-Ring - 1 Rubber 0.925" diam. Buy

4150 Plunger Retainer 1011 1 Aluminum 0.42" x 1.2" Make

4250 Lock Nut 4007 1 Aluminum 0.21" x 1.00" Buy

PARTS LIST


Bill of Materials


Route Sheet

Oper.

No.

Operation

Description

Machine

Type

Tooling Setup

(hr.)

Oper.

Time

(hr.)

Mtls.

Parts

0104 Shape, drill,

cut off

Auto sc.

Machine

.5 in dia coller, cir.

Form tool, .45”

diam center drill

5 0.0057 Alum

1”x12’

0204 Machine Slot

and thread

Chucker 0.045” slot saw,

turret slot

2.25 0.0067

0304 Drill 8 holes Auto dr.

unit

0.078” diam twist

drill

1.25 0.0038

0404 Debur and

Blow out

Drill press Deburring tool with

pilot

0.5 0.0031

SA 1 Enclose

subassembly

Dennison

hydraulic

press

None 0.25 0.0100

Company: ARC Inc.

Produce: Air Flow Regulator

Part: Plunger Housing

Part No. 3254

Prepared by: JSU

Part No. 6/6/03


Routing sheet MASTER ROUTING LIST MASTER ROUTING LIST

--PART NUMBER-- ---------DESCRIPTION---------- DATE ALT CODE BUYER/PLANNER --PART NUMBER-- ---------DESCRIPTION---------- DATE ALT CODE BUYER/PLANNER

DRAWING REVISIONDRAWING REVISION

H6709 HANDLE,DENSPLY PROBE 6/25/92 B 239 H6709 HANDLE,DENSPLY PROBE 6/25/92 B 239

G G

--------STANDARD-------- --------STANDARD--------

TIME MOVETIME MOVE

OPER WORK OPER SETUP CREW MACH --TOOLING REF-- --SETUP- -LABOR- -MACHINE-- I/O OPER WORK OPER SETUP CREW MACH --TOOLING REF-- --SETUP- -LABOR- -MACHINE-- I/O

BASIS TIME -----EFFECTIVE----BASIS TIME -----EFFECTIVE----

& ALT CENTER CODE CODE FACTOR GROUP NUMBER HOURS HOURS HOURS & ALT CENTER CODE CODE FACTOR GROUP NUMBER HOURS HOURS HOURS

CDE/-QTY- -DAYS- FROM TOCDE/-QTY- -DAYS- FROM TO

10 01226 1.0 01226 T9330 12.000 336.880 336.880 4 10 01226 1.0 01226 T9330 12.000 336.880 336.880 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99

PARTIAL AHEAD QTYPARTIAL AHEAD QTY

----------ROUTING DESCRIPTIONS---------- ----------ROUTING DESCRIPTIONS----------

MAKE @ AUTO 804843P MAKE @ AUTO 804843P

C 804843P B C 804843P B

A A02247 A A A02247 A

15 02053 1.0 02053 T9712 1.500 41.670 83.330 4 15 02053 1.0 02053 T9712 1.500 41.670 83.330 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99



DRILL & TAP 804843P1 DRILL & TAP 804843P1

B 804843P1 A B 804843P1 A

20 02053 1.0 02053 T9713 1.500 8.330 16.670 4 20 02053 1.0 02053 T9713 1.500 8.330 16.670 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99



KNURL OD KNURL OD

30 03029 1.0 .000 33.330 33.330 4 30 03029 1.0 .000 33.330 33.330 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99



SCOTCHBRITE/BELT SCOTCHBRITE/BELT

40 03105 1.0 03105 .000 3.000 3.000 4 40 03105 1.0 03105 .000 3.000 3.000 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99



PASSIVATE PASSIVATE

50 03005 1.0 .000 54.170 54.170 4 50 03005 1.0 .000 54.170 54.170 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99



BUFF BUFF

60 03007 1.0 03007 .000 50.000 50.000 4 60 03007 1.0 03007 .000 50.000 50.000 4

1000 .000 0/00/00 99/99/991000 .000 0/00/00 99/99/99



GLASSBEAD KNURL/ SHIP GLASSBEAD KNURL/ SHIP


Tools Used in Process Design

• Sequencing the Required Processes:

– Assembly Charts

– Operations Process Charts

– Process Flowcharts and Process Maps

– Precedence Diagrams


Analog model of the assembly process.

• Circles denote components

• Links denote

operations/subassemblies

• Squares represent inspections

operation

• Begin with the original product and

to trace the product disassembly

back to its basic components.

Assembly Chart 2200

3254

3253

3252

3251

3250

3255

4150

4250

A-1

Pack

SA-1

A-2

A-3

I-1 1050

A-4


Found by superimposing

the route sheets and the

assembly chart, a chart

results that gives an

overview of the flow within

the facility.

Operations Process Chart www.aeunike.lecture.ub.ac.id

Process Flowcharts

Reserve Storage

Quality Assurance

Back to Vendor

UPS

Parcel Post

Next-Day UPS

Mono-gramming

Embroid-ering

Hemming

Gift Boxing

Receiving Active Bins

Picking Packing Shipping


Process Maps

Place order

Drink

Eat salad or soup

Eat dinner

Receives check

Gives payment to waiter

Collect change, leave tip

Fill in tip amount

Give order to waiter

Prepare dinner order

Prepare soup or salad order

Give order to waiter

Is order complete?

Give soup or salad order to chef

Give dinner order to chef

Get drinks for customer

Deliver salad or soup order to customer

Deliver dinner to customer

Deliver check to customer

Receive payment for meal

Cash or Credit?

Bring change to customer

Run credit card through

Return credit slip to customer

Collect tip

Y

N

Credit

Cash

Customer Waiter Salad Chef Dinner Chef


SCHEDULE DESIGN


http://www.observer.co.za/article/overall-outlook-motor-industry-remains-positive

Schedule Design

Answering questions:

• HOW MUCH to produce => lot size

• WHEN to produce => production scheduling

Depend on:

• How long production will continue

Impacts:

Machine selections, #machines, #shitfs, #employees, space requirements, storage equipment, MH equipment, personnel requirements, storage policies, unit load design, building size, etc.


Marketing Information • Minimum market information required for Facilities Planning:


Marketing Information • Valuable information that should be obtained from marketing and used

by a Facilities Planner:


Process Requirements

• Schedule design determines the number of each equipment type required to meet the production schedule.

• Specification of process requirements typically occurs in three phases:

1. Determines the quantity of components that must be produced, including scrap allowances, in order to meet market estimate

2. Determines the equipment requirements for each operation

3. Combines the operation requirements to obtain overall equipment requirements



• SCRAP ESTIMATES 𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒖𝒏𝒊𝒕𝒔 𝒑𝒓𝒐𝒅𝒖𝒄𝒕𝒊𝒐𝒏

= 𝒎𝒂𝒓𝒌𝒆𝒕 𝒆𝒔𝒕𝒊𝒎𝒂𝒕𝒆 + 𝒔𝒄𝒓𝒂𝒑 𝒆𝒔𝒕𝒊𝒎𝒂𝒕𝒆

– Scrap: the material waste generated in the manufaturing process due to geometric or quality considerations


Process Requirements • SCRAP ESTIMATES


Process Requirements – Non Series Part A Part B

M1 p1=1% 1

M2 2 p2=2%

M2 p3=2% 3

M3 p4=1% 4

M4 p5=4% 5

100,000 units

451,10899.

366,107

1

366,10798.

219,105

1

366,10798.

219,105

1

219,10599.

167,104

1

167,10496.

000,100

1

1

11

2

22

3

33

23

4

44

4

5

55

p

PS

p

PS

p

PS

PPp

PS

Pp

PS

Work backward from

end of the line.



• EQUIPMENT FRACTIONS The quantity of equipment required for an operation

Total time required to perform the operation divided by the time available to complete the operation




• EQUIPMENT FRACTIONS

H : Running time per periode

D : Lama waktu kerja per periode (8 jam/hari

untuk satu shift kerja)

DT : Down Time

ST : Set up Time per periode

)1(D

SD

D

HE TT

Efisiensi Proses (E)



Process Requirements • MACHINE ASSIGNMENT

PROBLEM

– Operator-Machine Charts • Tool for showing activity of both

operator and machine along a time line

• Also called “multiple activity chart”

• Example: – 1 minute to load

– 1 minute to unload

– 6 minute run cycle

– 0.5 minute to inspect and pack

– 0.5 minute to travel to another machine

Time Operator M1

0.5 U1 UNLOAD

1 U1 UNLOAD

1.5 L1 LOAD

2 L1 LOAD

2.5 I&P RUN

3 RUN

3.5 RUN

4 RUN

4.5 RUN

5 RUN

5.5 IDLE RUN

6 RUN

6.5 RUN

7 RUN

7.5 RUN

8 RUN

Cycle Time 8 min

Oper Idle 5.5 min

Mach. Idle 0 min

Prod. Rate 0.125 pc/min

ONE MACHINE

– Operator Machine Charts

Time Operator M1 M2 Time Operator M1 M2 M2

0.5 U1 UNLOAD RUN 0.5 U1 UNLOAD RUN RUN

1 U1 UNLOAD RUN 1 U1 UNLOAD RUN RUN

1.5 L1 LOAD RUN 1.5 L1 LOAD RUN RUN

2 L1 LOAD RUN 2 L1 LOAD RUN RUN

2.5 I&P RUN RUN 2.5 I&P 1 RUN IDLE RUN

3 T-2 RUN RUN 3 T-2 RUN IDLE RUN

3.5 U2 RUN UNLOAD 3.5 U2 RUN UNLOAD RUN

4 U2 RUN UNLOAD 4 U2 RUN UNLOAD RUN

4.5 L2 RUN LOAD 4.5 L2 RUN LOAD RUN

5 L2 RUN LOAD 5 L2 RUN LOAD RUN

5.5 I&P RUN RUN 5.5 I&P 2 RUN RUN IDLE

6 T-1 RUN RUN 6 T-3 RUN RUN IDLE

6.5 RUN RUN 6.5 U3 RUN RUN UNLOAD

7 RUN RUN 7 U3 RUN RUN UNLOAD

7.5 IDLE RUN RUN 7.5 L3 RUN RUN LOAD

8 RUN RUN 8 L3 RUN RUN LOAD

8.5 I&P 3 IDLE RUN RUN

Cycle Time 8 min 9 T-3 IDLE RUN RUN

Oper. Idle 2 min

Mach Idle 0 min Cycle Time 9 min

Prod Rate 0.25 pc/min Oper. Idle 0 min

Mach Idle 1 min

Prod Rate 0.333333 pc/min

TWO MACHINES THREE MACHINES


FACILITIES DESIGN


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Facilities Design

• Facilities planner :

– Organize:

• the information (product, process, and schedule design)

– Generate and evaluate:

• Layout design alternatives

• Handling design alternatives

• Storage design alternatives

• Unit layout design alternatives


Facilities Design

• Tools: – Pareto Chart

– Seven management and planning tools • Affinity diagram

• Interrelationship diagraph

• Tree diagram

• Matrix diagram

• Contigency diagram

• Activity network diagram

• Prioritization matrix


Affinity diagram • Is used to gather verbal data, such as ideas and issues, and organize it

into grouping


Interrelationship diagraph

• Is used to map the logical links among related items, trying to identify which items impact others the most. This graph helps us understand the logical sequence of steps for the facilities design.


Tree diagram • Is used to map in increasing detail the actions that need to be

accomplished in order to achieve a general objective.


Matrix diagram • Organizes information such as characteristics, functions, and tasks into

sets of items to be compared.

• Provides visibility to key contact on spesific issues and helps identify individuals who are assigned to too many teams.


Contigency diagram

• Process decision program chart, maps conceivable events and contigencies that might occur during implementation.

• Is useful when the project being planned consists of unfamiliar tasks.


Activity network diagram • Is used to develop a work schedule for the facilities design effort.

• Critical path method (CPM).

• Can be replaced by a Gant chart.

Prioritization matrix • In developing facilities design alternatives it is important to

consider: a) Layout characteristics

• Total distance travelled

• Manufacturing floor visibility

• Overall aesthetics of the layout

• Ease of adding future business

b) Material handling equipment • Use of current material handling equipment

• Investment requirements on new equipment

• Space and people requirements

c) Unit load implied • Impact on WIP levels

• Space requirements

• Impact on material handling equipment

d) Storage strategies • Space and people requirements

• Impact on material handling equipment

• Human factor risk

e) Overall building impact • Estimated cost of the alternative

• Opportunities for new business


Prioritization matrix • Is used to judge the relative importance of each criterion as compared

to each other

Logical application sequence of The seven management and planning tool

References

• Heragu, S. (2008). Facilities Design (3rd Ed.). CRC Press.

• Tompkins, White, Bozer and Tanchoco. (2010). Facilities Planning (4th Ed.). New York: Wiley.


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