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2.008 -Spring 2004 2
Outline
1. Manufacturing Systems
2. Types of Plant Layouts
3. Production Rates
4. Design and Operations
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2.008 -Spring 2004 3
Manufacture
Market
Research
Conceptual
Design
Design for
Manufacture
Unit
Manufacturing
ProcessesAssembly
and Joining
Factory,
Systems &
Enterprise
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2.008 -Spring 2004 5
Time spectrum of Typical Activities in a
Manufacturing OrganizationSeconds Period Activity
108 DecadePlant design, Machine Selection,
107 Year System Simulation
Process design: CAD106 Month Catalogs
Select manufacturing methodsWeek
105 DayFactory Operation
104 Ship-ReceiveHour Transport Inventory
103
102
Minute Part handling101 Load/Unload
Assembly1 Second
.1 Machine controlCNC-DNC
.01 Adaptive control
Intelligent machines.001 Millisecond Process control
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2.008 -Spring 2004 6
How Man, Machine, and Material Spend
Time in the Factory
People Materials Machines
Value-added
Value-added
Value-added
Waste Waste Waste
Waste: transportation, storage,
inspect on and rework"Waste": unnecessary
movement of machine, setup
time, machine breakdown,
unproductive maintenance,
producing defective products,
producing products when not
needed, etc.
"Waste": waiting for materials,
watching machine running,
producing defects, looking for
tools, fixing machine
breakdowns, producing
unnecessary items, etc
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2.008 -Spring 2004 7
Disruptions/Variation
(Random Events)
Machine failure
Set-up change
Operator absence
Starvation/Blockage
Demand change
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2.008 -Spring 2004 8
Types of Plant Layout
Job Shop
Project Shop
Flow Line
Transfer Line
Cellular System
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2.008 -Spring 2004 9
Job Shop
Machines/Resources
are grouped according
to the process they
perform
Raw Material
Ready part
A A
A A
D D
D D
D D
C C
C C
C C
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2.008 -Spring 2004 10
Project Shop
Machines/Resources
are brought to and
removed from
stationary part as
required
A
A
C
B
B
D
DD
Raw
material/
Ready part
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2.008 -Spring 2004 11
Flow Line and Transfer Line
Machines/Resources
are grouped in lines
according to the
processes sequence
of part(s)
A
A
Raw Material
Ready part
B
B
C
D
D F
F F
G
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2.008 -Spring 2004 12
Cellular System
Machines/Resources
are grouped
according to the
processes required
for part families
Raw Material
Ready part
B
B
C
E
E
A
D
D
D
F
F
G
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2.008 -Spring 2004 13
Production Quantity and Plant Layout
Project Shop
Job Shop
Cellular System
Flow Line
1 10 100 1,000 10,000 100,000
Quantity
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2.008 -Spring 2004 14
Production Rates
Case I:
One machine
Everything works
M
timeOperation1rateProduction !
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2.008 -Spring 2004 16
Production Rates (contd)
Case III:
Many machines
No machine breaks down
No buffers
M1 M2 Mi Mk
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Production Rates (contd)
Case IV:
Many machines (same operation time)
No machine breaks down
No buffers
M1 M2 Mi Mk
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2.008 -Spring 2004 18
Production Rates (contd)
Case V:
Many machines (same operation time)
Machine breaks down
No buffers
M1 M2 Mi Mk
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Production Rates (contd)
Case VI:
Many machines and buffers in between
Machine breaks down
M1 M2 Mi MkB1 B2 Bk-1Mk-1
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2.008 -Spring 2004 20
Production Rates (contd)
Production rate increases if:
Increase the rate of the slowest machine
Reduce the disruptions
Introduce buffers
Introduce in-process control
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2.008 -Spring 2004 21
Disruptions
(Random Events)
Machine failure
Set-up change
Operator absence
Starvation/Blockage
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2.008 -Spring 2004 22
Waiting
Underutilization
Idleness
Inventory
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2.008 -Spring 2004 23
Inventory/Work-in-Process (WIP)
It costs money
It gets damaged
It becomes obsolete
It shrinks
It increases lead time
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2.008 -Spring 2004 24
Cycle Time and Lead Time
Order
Supply
Order
Supply
PlantSupplier Customer
demanda erageailytimea aila leailytimeTakt !
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Cycle Time
Cycle Time
The time a part spends in the system
Littles Law: L = w
L: average inventory
: average production rate
w: average cycle time
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Cycle Time (contd)
Example:
Operation time = 1, One-piece operation
Production rate = 1
Cycle time = 5
Inventory = 5
M1 M2 M3 M5M4
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Cycle Time
Batch Production
1.
Operation time: 3 minutes
Batch (Lot) size: 1000Cycle time = 1,000*3 + 1,000*3 + 1,000*3 = 9,000min
Op1 Op2 Op3
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Cycle Time
One-Piece Production
2.
Operation time = 3 minutesCycle time = 1,000*3 + 2*3 = 3,006 minutes
Op1 Op2 Op3
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2.008 -Spring 2004 29
Cycle Time and Lead Time
Order
Supply
Order
Supply
PlantSupplier Customer
demandaverageDaily
timeavailableDailytimeTakt !
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2.008 -Spring 2004 30
Systems Design and Operation
Cycle time < Lead time
Lumpiness
Information contents
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Typical Design Guidelines
Leveling
Balancing
Single-piece flow
Low materials handling
Low setup time
Smaller lot size
Low WIP
Faster feedback
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