Methods, Standards, and Work Design

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Presentation transcript:

Methods, Standards, and Work Design Products and Facilities Chapter 3 Methods, Standards, and Work Design 11th Edition Niebel/Freivalds

Concurrent Engineering Defined the simultaneous development of project design functions open and interactive communication existing among all team members for the purposes of: reducing time to market, decreasing cost, and improving quality and reliability

Design for Manufacturing and Assembly Greatest improvements related to DFMA arise from simplification of the product by reducing the number of separate parts: 1. During the operation of the product, does the part move relative to all other parts already assembled? 2. Must the part be of a different material or be isolated from other parts already assembled? 3. Must the part be separate from all other parts to allow the disassembly of the product for adjustment or maintenance?

Types of Processes Conversion - changing iron ore into steel Fabrication - making car bumpers from plastic Assembly - assembling a car Testing - computer boards - not a fundamental process

Process Flow Structures Job shop - small batches of a large number of different products printing, machine shop, tool & die Batch shop - standardized job shop, products produced in batches clothing Assembly Line - parts move from station to station at a controlled rate microwaves, cars Continuous Flow - continuous versus discrete flow beer, paint

IV. Continuous Flow III. Assembly Line II. Batch I. Job Shop Low Exhibit 5.10 IV. Continuous Flow III. Assembly Line II. Batch I. Job Shop Low Volume, One of a Kind Multiple Products, Volume Few Major Higher High Standard- ization Commercial Printer French Restaurant Heavy Equipment Coffee Shop Automobile Burger King Sugar Refinery Flexibility (High) Unit Cost (High) Flexibility (Low) Unit Cost (Low)

Basic Production Layout Formats Process Layout Product Layout Group Technology (Cellular) Layout Fixed-Position Layout

Flow Through Systems

Process-Oriented Layout Design places departments with large flows of material or people together Dept. areas have similar processes e.g., All x-ray machines in same area Used with process-focused processes Examples Hospitals Machine shops © 1995 Corel Corp.

Process-Oriented Layout Floor Plan Office Table Saws © 1995 Corel Corp. Drill Presses Tool Room © 1995 Corel Corp.

Product-Oriented Layout Facility organized around product Design minimizes line imbalance Delay between work stations Types: Fabrication line; assembly line Examples Auto assembly line Brewery Paper mfg. © 1984-1994 T/Maker Co.

Product-Oriented Layout Floor Plan 1 3 Operations 4 5 2 Belt Conveyor Office

Cellular Layout - Group Technology (Work Cells) Special case of process-oriented layout Consists of different machines brought together to make a product Group Technology Benefits: Better human relations Improved operator expertise Less in-process inventory and material handling Faster production setup

Work Cell Floor Plan Saws Drills Office Work Cell Tool Room

Fixed-Position Layout Design is for stationary project Workers & equipment come to site Complicating factors Limited space at site Changing material needs Examples Ship building Highway construction © 1995 Corel Corp. © 1995 Corel Corp. © 1995 Corel Corp.

Fixed Position Layout Question: What are our primary considerations for a fixed position layout? Answer: Arranging materials and equipment concentrically around the production point in their order of use.