FACILITIES PLANNING AND DESIGN

Product, process and schedule design28-June 2015

Product designers specify what the end product is to be in terms of dimensions, material composition, and perhaps, packaging. The process planner determines how the product will be produced. The production planner specifies the production equipment the facilities planner is dependent on timely and accurate input from product, process, and schedule designers to carry out his task effectively.

Product DesignProduct design involves both the determination of which products are to be produced and the detailed design of individual products.Exploded assembly drawings, such as given in figure 4.2, are quite useful in designing the layout and handling system. These drawings generally omit specifications and dimensions, although they are drawn to scale.

Exploded assembly drawingProduct DesignExploded Part photographphotographs and drawings allow the planner to visualize how the product is assembled, provide a reference for part numbers, and promote clearer communications during oral presentations.

Product Design

Detailed component part drawings are needed for each component part. The drawings should provide part specifications and dimensions in sufficient detail to allow part fabrication. The combination of exploded assembly drawings and component part drawings fully documents the design of the products.Drawings can be prepared and analyzed with computer aided design (CAD) systems. CAD is the creation and manipulation of design prototypes on a computer to assist the design process of the product.concurrent engineering (CE) can be used to improve the relationship between the function of a component or product and its cost. CE provides a simultaneous consideration in the design phase of life cycle factors such as product, function, design, materials, manufacturing processes, testability, serviceability, quality, and reliability.Process DesignDetermination of how the product is to be producedWho should do the processing? (Which part of the products should be made?)How the part will be produced?Which equipment will be used? (for the parts which will be made in-house)How long will it take to perform the operation?

Production methods are the most fundamental factor affecting the physical layout Process DesignWithin the process design process, we need to consider following issues1.Process identificationMake-or-buy analysisParts identification2.Process selectionHow the product will be made (operations, equipment, raw material, etc.)3.Process sequencingHow components are put together

Process Design I. Process IdentificationMake-or-buy decisionsThe scope of the facility depends on the level of vertical integrationHow are the make-or-buy decisions made?Can the item be purchased?Should we go for subcontracting?SupplierContractorCan we make the item?Is it cheaper for us to make than to buy?Is the capital available so that we can make it?Managerial decisions requiring input from finance, industrial engineering, marketing, process engineering, purchasing, human resources, etc.

Process Design I. Process IdentificationThe input to the facility planner is a listing of the items to be made/purchased.Parts list component parts of a product:part numberspart namenumber of parts per productdrawing referencesBill of materials -structured parts list: contains hierarchy referring to the level of product assembly

Process Design- 2. Process SelectionHow the products will be made6-step procedure:1.Define elementary operations2.Identify alternative processes for each operation3.Analyze alternative processes4.Standardize processes5.Evaluate alternative processes6.Select processes

Process Design- 2. Process SelectionRoute sheet -output of process selection, it identifies processes, equipment and raw materials

Process Design- 2. Process Selection

Process Design 3. Process SequencingThe method of assembling the productAssembly chart shows how the components are combinedOperation process chart gives an overview of the flow within the facilityA combination of route sheets and assembly chartsPrecedence diagram establishes precedence relationships

Schedule DesignSchedule design provides answers to questions involving:Production quantity -lot size decisionsWhen to produce -production schedulingHow long to produceSchedule design decisions impact machine selection, number of machines, number of shifts, number of employees, space requirements, storage equipment, material handling equipment, personnel requirements, storage policies, unit load design, building size, etc.

Schedule DesignWe design facilities for major parts and operationsWhat do we need to know to start designing our facilitiesNumber of products demanded by the marketNumber of products to be producedNumber of machines requiredNumber of employees requiredSequence of operationsRelationships between departments

Schedule Design Marketing InformationObjective market estimateData from marketing:Production volumesTrendsFuture demands

Schedule Design Marketing Information

Schedule Design Process requirementsSpecification of process requirements has three phases:Determination of the quantity to be manufactured for each componentIdentification of each equipment required by each operationOverall equipment requirements

Process Requirements Quantity DeterminationScrap EstimatesDetermination of the quantity to be manufactured for each componentFor high volume productionThe estimation of scrap

Reject Allowance ProblemDetermination the number of additional units to allow when the number of items to produce are very few and rejects randomly occurFor low volume productionThe cost of scrap is very highScrap EstimatesThe market estimate specifies the annual volume to be produced for each product. To produce the required amount of product, the number of units scheduled through production must equal the market estimate plus a scrap estimate.Scrap is the material waste generated in the manufacturing process due to geometric or quality considerations.Scrap Estimates

Scrap Estimates

Equipment FractionsThe quantity of equipment required for an operation

Equipment Fractions

Machine Assignment ProblemHuman-machine Chart or Multiple Activity ChartUsed to analyze multiple activity relationships when non identical machines are being tended by one or more operators.Machine Assignment ProblemTravel 0.5 minuteLoad 1 minuteUnload 1 minuteMachine Time 6 minutesInspection and Packing 0.5 minute

Machine Assignment ProblemFormulas:n=(a+t)/(a+b)

Machine Assignment Problem Where:

Facilities Design 7 Management and Planning Tools

Facilities Design 7 Management and Planning Tools

Facilities Design 7 Management and Planning Tools

Facilities Design 7 Management and Planning Tools

Facilities Design 7 Management and Planning Tools

Facilities Design 7 Management and Planning Tools

Facilities Design 7 Management and Planning Tools

Facilities Design 7 Management and Planning Tools

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