Manufacturing Planning Elena Joshi Industrial and Manufacturing Engineering
How Should the Product Be Made? Production planning Factory layout Production Scheduling Warehousing Delivery to customers
Example: Automobile Final Assembly Production Planning What operations are required? In what sequence should they be performed? How can they be combined into assembly stations? How is product quality maintained?
Example: Automobile Final Assembly Factory layout Which operations are automated? What equipment is required? How will the vehicle be moved? How will parts be delivered
Example: Automobile Final Assembly Production Scheduling How many cars per hour? Where are bottlenecks? How are people scheduled? How are different models scheduled?
Example: Automobile Final Assembly Warehousing How much space? How much inventory? Delivery to customer Method of delivery Defect monitoring
A Simple Production Line Make booklets Inspect booklets Warehouse and deliver to customer
Your Task Operate the line Evaluate the performance of the line Suggest improvements Implement improvements Observe results
Line Operations Punch: Take 2 sheets of paper & punch 2 holes at the top (must be of the same color) Tie: Use a matching color tie, one for each hole Color: Use a matching color crayon and color inside the lines Inspect: Reject if coloring outside the lines Reject if both pages are not the same color Reject if marker or tie color is wrong Reject if holes are ripped to edge Warehouse: Store products until needed Transport batches: Move items between operations. Items must be moved 2 at a time, both same color
Other Tasks Customer: Ask warehouse for matching product every 30 seconds. Warehouse must deliver product before the next item is demanded Accountant: Keep track of all sales -- each sale creates a profit of $10. At the end, count scrap -- each scrapped item costs $6. At the end, count all products in the warehouse -- each of these has a storage cost of $1
LAYOUT OF THE CLASS warehouse Customer Color Punch Inspection Tie Accountant Accountant Color Punch Transport Transport Inspection Tie