1. Industrial Facilities Design 7 th Term, Batch:2010 04/03/20131Lect#1,2

2. Recommended Books: 1.MANUFACTURING FACILITIES: Location, Planning & Design By:D. R. Sule …………………………………………….2 nd Edition 2.FACILITIES DESIGN By: Suderesh Sesharanga Heragu ………….…2 nd Edition. 3.FACILITIES PLANNING By: Tomkins & White, John Wiley …..….….. Any latest edition 4. OPERATIONS MANAGEMENT By: Ritzman………………………………………………Any latest edition 5. OPERATIONS MANAGEMENT By: Joseph G. Monks………………………………… 2 nd Edition 04/03/20132Lect#1,2

3. Objectives & Scope of the Subject: To cover all phases of manufacturing within the plant such as: designing a product choosing manufacturing processes Developing Production Systems & Associated Plant Layout Designing material handling & storage systems Selecting the essential labor resources to operate the plant 04/03/2013Lect#1,23

4. Objectives & Scope of the Subject: Considering the cost factors that go into the design and operation of plant Basic location/allocation analysis 04/03/2013Lect#1,24

5. Introduction Facilities: Defn- “Buildings where men, material and machines come together for a stated purpose” Typically it is to make a tangible product or provide a service Prime factors of effective facilities are lower cost, higher quality, & Using the less amount of natural resources 04/03/2013Lect#1,25

6. Introduction Designing a Mfg plant is a bold undertaking that necessitates many complex decisions, each of which significantly affects the profitability of the venture In broad generalities, we must select a product, design it, produce it, sell it. Besides financial consideration of raising capital numerous decisions must be made in each step that affect the time & cost of manufacturing the product 04/03/2013Lect#1,26

7. Introduction (Continue) eg: Improper design or layout of a plant can add considerably to the cost of manufacturing. It may increase the throughput time, setup times, & in process inventories, & may contribute to the over all inefficiency of operations. For repeated high-volume & tedious jobs, use of robots might reduce production cost, but the same robot could actually add to the cost if the facility must handle many different jobs, each with different characteristics & having a low volume of production 04/03/2013Lect#1,27

8. Historical Development DateEvent 4000 B.CEgyptians developed expertise in finding suitable locations for pyramids according to their astrological calculations 100 B.C- 100 A.D Romans developed full-fledged methods for construction of temple, arenas, & other buildings. Detailed planning of public & residential buildings 1700- 1900 Industrial Revolution Period 1910First Industrial Engineering Text book “Factory Organization & Administration published by Hugo Diemer 1913First moving automotive assembly line introduced by Henry Ford 1954Quadratic assignment problem for micro - & macro-level location problems introduced by Koopmans & Beckman 04/03/2013Lect#1,28

9. Historical Development (Cont..) DateEvent 1955- 1995 Optimal & heuristic algorithms for the quadratic assignment problems were used 1959Systematic Layout Planning (SLP) approach introduced by Muther 1963CRAFT(Computerized Relative Allocation for Facilities Technique) introduced by Armour and Buffa Early 1980s The Flexible Manufacturing System concept is introduced & attention shifts towards achieving plant-wide flexibility via medium-volume, medium-variety production using cellular manufacturing techniques Late 1980s The term automation introduced to cope with plant flexibility requirements 1985- present Modern software for facility design problems 1990s- present Research on new layout concepts including dynamic layouts, robust layouts & reconfigurable layouts introduced to support mass customization Techniques 04/03/2013Lect#1,29

10. Typical Design Problems in Automated Manufacturing Systems 04/03/2013Lect#1,210 Facility Location Type, volume of products to be manufactured Manufacturing Processes required Design of components Type, Number of equipment required Process Planning Tooling, Fixture, Determination Determination of M/c Cells Layout of M/c Cells

11. Typical Design Problems in Automated Manufacturing Systems (Cont..) Layout of equipment within each cell Determining material handling methods Type, number of material handling devices Determining flow of products Scheduling & Planning of jobs Overall System Design Inventory Control Distribution of goods Quality Control 04/03/2013Lect#1,211

12. Typical Design Problems in Automated Manufacturing Systems (Cont…) Design Problems are those that are taken rather infrequently. They are addressed once in 3 to 5 years or more bcz it is costly to alter a design decision frequently. Eg: once a plant is built in a certain geographic area, it is difficult to justify moving the plant to an other location within 1 or 2 years of the 1 st decision bcz the fixed costs would not have fully recovered within this time period. Similarly, if heavy duty m/cs have already been laid out in a plant, we have to live with that layout for a period of at least 3 to 5 years 04/03/2013Lect#1,212

13. The Role of Facility Planner Facility Planner: “The person responsible for coordinating different departments & achieving efficiency in manufacturing operations” Designation of Facility Planner: For small plants: Supervisor, Manager, Even the president of the company For large Plants: Facility manager, or planner 04/03/2013Lect#1,213

14. The Role of Facility Planner (Cont..) Responsibility: To develop efficient plant layout & material handling systems; to integerate many tasks & operations within manufacturig Roles: 1. FP may participate in design & development of quality products that satisfies a known market demand & can be produced efficiently in the plant. 04/03/2013Lect#1,214

15. The Role of Facility Planner (Cont..) Roles (cont..) : 2.FP may help select economic processes to manufacture the product & specify the necessary m/cs & qualifications of the labor to operate these m/cs. 3.They may formulate the production policies & specify the degree & type of automation 4. They may develop the plant layout, define the direction of material flow & select the material handling eqpt to accomplish the material transfer 04/03/2013Lect#1,215

16. The Role of Facility Planner (Cont..) Roles (cont..): 5.They may develop the locations for in-process storage & determine their capacities 6. They may determine the areas needed for storage & warehousing, design their layouts, & formulate their operating policies 7. they may be responsible for monitoring the environmental & worker safety against the stated standard laid down by regulating agency 04/03/2013Lect#1,216

17. The Role of Facility Planner (Cont..) Roles (cont..): 8. They may also be responsible for keeping the cost of insurance, taxes, & health care within limits 9. FP coordinate sales, engineering, personnel with production & operations activities such as planning, scheduling, & controlling & contribute to management of these areas 04/03/2013Lect#1,217