1. Manufacturing Planning
Elena Joshi
Industrial and Manufacturing Engineering

2. How Should the Product Be Made?
Production planning
Factory layout
Production Scheduling
Warehousing
Delivery to customers

3. 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?

4. 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

5. Example: Automobile Final Assembly
Production Scheduling
How many cars per hour?
Where are bottlenecks?
How are people scheduled?
How are different models scheduled?

6. Example: Automobile Final Assembly
Warehousing
How much space?
How much inventory?
Delivery to customer
Method of delivery
Defect monitoring

7. A Simple Production Line
Make booklets
Inspect booklets
Warehouse and deliver to customer

8. Your Task Operate the line Evaluate the performance of the line
Suggest improvements
Implement improvements
Observe results

9. 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

10. 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

11. LAYOUT OF THE CLASS warehouse Customer Color Punch Inspection Tie
Accountant
Accountant
Color
Punch
Transport
Transport
Inspection
Tie