Presentation on theme: "By Anastasia Lidya Maukar"— Presentation transcript:
1 By Anastasia Lidya Maukar Facility Design – Week 2 Product, Process and Equipment Design and AnalysisByAnastasia Lidya Maukar
2 Data required for developing good layouts Product AnalysisProcess Analysis
3 Product AnalysisProduct analysis is to determine the product process sequenceThe information about the product can be generated from:PhotographBill of MaterialEngineering DrawingAssembly ChartRoute SheetOperation Process Chart
6 Engineering DrawingThe part list includes the following information for each piece required for the final assembly:piece numberpiece namequantity required for the final assemblymaterialstock size of the raw materialif neededdetail drawing numbersweightany other pertinent details
7 Engineering Drawing of the Gate Valve Provide part specifications and dimensions in sufficient detail for manufacturing
8 Parts List of the Gate Valve The parts list provides a listing of the component parts of a product. In addition to make or buy decisions, a parts list includes part number, part name, number of parts per product, and drawing references
9 Bill of MaterialA bill of material displays a list of parts and are directly required to make a complete assembly.At minimum it should indicate, for each partits number (or drawing number)its descriptionthe quantity necessary in the assemblythe part is to be made or buyThe listing may include additional information such as:material descriptionweightunit price
11 Bill of MaterialProduct — An item sold directly to customers (products are listed in the Company catalog).Assembly - A part that is made of two or more other parts and associated labor. The parts, in turn, may be other assemblies, components, materials or products.Component - A part that is made on the shop floor (also defined as material on which labor has been performed). Some companies use the terms Assemblies and Components interchangeably in their discussions of Bills of Material structure. Defining them separately is preferable.Material - The type and size of raw material from which a part is made, such as 3/4x48x120 particle board or 6-inch brass railing, or a purchased part. Material is always purchased.
12 Assembly Chart IAn assembly chart gives a broad overview of how several parts manufactured separately are to be assembled to make the final product.It is an analog model of the assembly process. Circles with a single link denote basic components, circles with several links denote assembly operations/subassemblies, and squares represent inspection operations.
14 Route SheetA route sheet specifies the operations required for a part as well as the sequence of the machines visited for these operations.It may also provide the set-up time for each machine, processing time and labor time.It shows how a part is to be produced, which machine are needed, the tools to use, estimated setup times for the machines and production in terms for the machines and production in terms of the number of units expected per hour from each machine.One routing sheet is required for each part in the assembly.
15 Route Sheet for one Component of the Gate Valve Route sheet summarizes whether a part will be purchased or produced, how the production of a part will be achieved, what equipment will be used, and how long it take to perform each operation.
16 Operations Process Chart By superimposing the route sheets and the assembly chart, a chart results that gives an overview of the flow within the facility. This chart is the operations process chart.
17 Precedence Diagram for Assembling the Gate Valve A precedence diagram establishes the prerequisite assembly steps that must be completed before performing a given assembly step.
18 Process Design & Analysis It is a design or analysis of how a product and its componets are produced.The information consists of:Operation sequence of each product/part (included make or buy analysis for each part)Machine, equipment, tools, fixtures, etc.Operation sequence of assemblies and packout.Standard time for each work element.
19 Process Design & Analysis Determining the conveyor rate, assembly and packout lines and painting/finishing systemLine balancing for each assembly and packout lines.Load work cells.Developing of workstation drawing for each operation using motion economy and ergonomics.
21 Make-or-Buy Reasons to make Cheaper to make Company has experience making itIdle production capacity availableCompatibility and fit with company’s planned lines of businessPart is proprietaryWish to avoid dependency an outside supplierPart fragility requiring high packing and transportation CostsTransportation costs are high
22 Make-or-Buy Reasons to buy Cheaper to buy Production facilities are unavailableAvoid fluctuating or seasonal demandInexperience with manufacturing processExistence and availability of suppliersMaintain existing supplier relationshipHigher reliability and quality
23 Machine & Equipment Selection The Number of Machines Needed? These questions can be answered when we know:How many finished goods are needed per day?Which machine runs what parts?What is the time standard for each operation?
24 Machine & Equipment Selection Advantage:Make efficient use of capital equipment purchase budgetMake efficient use of maintenance and operating budgetIncrease machine utilizationMake efficient use of available space
25 Calculation of Number of Machine p = production rates(units/day) τ = working hours per day(hours)η = machine efficiency t = operation time(hours)Using Backward Analysis (for the sequencing production processws) and each process has a certain scrap, number of production unit to fulfill the demand :Sl = % scrap pf process l Nol = number of output for process lNil = number of input for process l
26 Calculation of machine requirements 123P1P2P3INPUTOUTPUTNilNil = Nol + ScrapScrapNol
27 Personnel Requirement Analysis N = number of types of operationsOi = aggregate number of operations of type i required on all the pseudo/real products manufactured per dayTi = standard time for an average operation OiH = total production time available per dayη = assumed production efficiency of the plant
28 Space Requirement & Availability Space for facilitiesSpace for operator movement, loading & unloading partsSpace for incoming material & WIPSpace for auxiliary equipmentSpace for future expansion and growth