SUBJECT  Industrial facility design

GROUP MEMBERS H.Hammad Ali 11-IE-32 S.Hammad shah 11-IE-21 Hammad Hassan 11-IE-41

Introduction Facility Planning: The process of identifying the needs of facility users in order to create a project design that meets those needs.

Facility plan Process Facility planning process for manufacturing and assemble the products.  Define the Product  Specify the required Manufacturing  Determine the interrelationship  Determine the space requirements  Generate the alternative FP  Evaluate the FP  Implement the FP  Maintain and adapt the FP  Update the products

Alternative Facility Plan Facilities can be broadly defined as buildings where people, material, and machines.... Evaluate alternative facilities plans (alternative locations and alternative). Before the alternative facility plan answered the some questions.  What is to be produced?  How are the products to be produced?  When are the products to be produced?  How much each product to be produced?  How long the products to be produced?  Where are the products to be produced?

Global Sourcing A procurement strategy in which a business seeks to find the most cost efficient location for manufacturing a product even if the location is in a foreign country. Examples  An Automobile Industry  An toy Industry  Textile Industry

PP&S Design  Product Design  Process Design  Schedule Design

Product Design  Both the Determination  Decision and Upper level management

Dynamic Product Environment  In Which it is not possible to accurately specify the products to be produced in a given facility.

Design of the Product  The design of the product is influenced by aesthetic, material ……  Meet the needs of the costumer.

Quality Function Deployment  Organized planning approach  To identify customer needs  To translate needs of product charactaristics,product design and tolerance requirements.

Benchmarking  What the Competition is doing to satisfy the customer needs.  Exceeds customer expectations

Exploded Assembly Drawing  An exploded view drawing is a diagram, picture or technical drawing of an object, that shows the relationship or order of assembly of various parts.

Computer Aided Design  Computer-aided design (CAD) is the use of computer systems to assist in the creation, modification, analysis, or optimization of a design.

Concurrent Engineering  To improve relationship b/w the function of the component or product and its cost.  Concurrent engineering provides a simultaneous consideration in the design face of cycle factor such as product, function, material, design, manufacturing and quality.

Example #2.1 Calculating the production requirements for a serial process with three operations A product has a market estimate of Requires three processing steps (drilling, milling, turning ) having defective estimates. D1=0.04 D2=0.01 D3=0.03 Find the Inputs? Using Formula Ok=Ik-dk

Process design How product is produced? Manufacture or Buy? Equipment? Time required?

Steps in process design Identify required process Selecting the required process Sequencing the required process

Identifying required process Determine the scope of facility. Downsize large facilities. Make or buy decision should take input from: - Finance, marketing, industrial engineering, process, purchasing, HR and others.

List the items that needs to buy or manufacture on a bill of material.

While making a bill of materials, in addition to make-or-buy decision, parts list atleast include the following - Part number - Part names - Number of parts per product - Drawing references

Selecting the required process Make-or-buy decisions are based on - previous experiences - related requirements - available equipments - production rates

Bill of material for an Air flow regulator

Process Identification: It consists of description of what is to be accomplished, what is to be manufactured, part drawings describing each component, quantities to be produced. Computer aided process planning: Can be used to automate the manual process planning.

Types of CAPP: Variant Standard process plans for each part and stored within computer. It is less expensive and easy. Generative Process plans are generated automatically for new components without requiring existing plans.

Steps in process selection: Define elemental operations Identify alternative processes for each operation Analyze alternative processes Standardize process Evaluate alternative process Select process

Sequencing the required process Assembly chart: Document the method of assembling the product. The easiest method to construct is to begin with completed product and to trace disassembly back to its basic components.

Assembly chart

Operations Chart To construct, begin with the upper right side of chart with components as first assembly operations. It can be complemented with transportation, storages and delays. It gives an overview of the flow within the facility.

Precedence diagram Operation chart as a special case of more general graphical model is called precedence diagram. It establishes the precedence relationships that must be maintained in manufacturing and assembling a product.

Group technology GT refers to grouping part into families, and then making design decisions. It is based on part shapes, sizes, material type and characteristics.

Schedule design How long production will continue? When to produce? How much to produce?

Schedule design decision impacts on - machine selection - number of machines - number of employees - space requirements - storage equipment - material handling equipment etc

Marketing information It determines how long the production will continue. It is the information regarding the dynamic value of a demand of product.

Pareto analysis Pareto, observed that 85% wealth of the world is held by 15% of the people. It is depicted in volume-variety chart.

It suggests that facility plan should consist of mass production for the 15% of high volume items.

Specifications of Process requirements typically occurs in three phases, 1 st Phase : Determines quantity that must be produced 2 nd Phase : Machine requirement 3 rd phase : combines the operation requirements to overall machine requirements

Calculations of Production Requirements Let d k represents the percentage of defects produced in k th operation O k Desired output without defects I k production Input O k = I k – Defectives Defective Parts = I k × d k Ok = I k – d k I k = I k (1-d k )

Once the product, process & schedule design decisions have been made the facility planner needs to organize the information and generate and evaluate layout, handling, storage and unit load design alternatives.

1.Affinity Diagram 2.Interrelationship Digraph 3.Tree Diagram 4.Matrix Diagram 5.Contingency diagram 6.Activity Network Diagram 7.Prioritization Matrix

Gather verbal data & organize it in groups

Affinity Diagram

Form Product Families Assign Families to manufacturing Cell Keep receiving & shipping close to Production Assign Raw material to their point of use

The tree diagram is used to map the increasing detail the action that need to be accomplished in order to achieve the objective.

It organizes information such as characteristics, functions and tasks into set of items to be compared. This tool provides visibility to key contacts to specific issues and help to identify individuals who are assigned to too many teams.

Team / Participants Joe MaryJerryAnnaLindaDaisyJack Part Usage TeamPCPLP Machine use teamLCP Demand Forecast Team PCL L=Team Leader C=Team Coordinator P=Team Participant

Contingency Diagram Also Known as process decision program chart. It maps conceivable events & contingencies that might occur during Implementation. It’s useful when project consists of Unfamiliar tasks.

Contingency Diagram

Used to develop a work schedule for the facilities design. CPM (Critical Path Method) Gantt Chart PERT (Program evaluation & Review Technique)

Prioritization Matrix  In Facility Design it is important to consider: Layout characteristics Material Handling Requirements Unit load Implied Storage strategies Over all Building Impact