1. 10/13/2015 IENG 471 Facilities Planning 1 IENG 471 - Lecture 06 Flow: Quantitatively and Qualitatively Measured

2. 10/13/2015IENG 471 Facilities Planning 2 Space Considerations Equipment footprint Utilities space Maintenance space Operating space (Operator space is discussed AFTER Exam I) Material space Tooling space Scrap space Work-In-Process (WIP) Receiving Space Shipping Space Plus Material Transportation! Depends on cell production rate and on production control policy for material flow

3. 10/13/2015IENG 471 Facilities Planning 3 Production Control of Flow Push Production: Traditional Build To Schedule Cell Efficiency Effects – Optimal Overall Efficiency Effects – Sub-Optimal Pull Production: JIT Kanban Production Card (POK) Withdrawal Card (WLK) Minimizes WIP (and a host of other problems!)

4. 10/13/2015IENG 471 Facilities Planning 4 Flow Factors What makes moving a thing difficult? Shapeawkward/compact Weightmass per unit SizeL x W x H Valuewood / gold Fragilitydelicate / sturdy Conditionsticky / hot / wet / frozen Equipmentfork truck / cart / crane Distanceshort / long / elevation change

5. 10/13/2015IENG 471 Facilities Planning 5 Flow Intensity Four Basic Factors of All Moves (Phillips) Materials Methods of handling Moves (distance & elevations) Moneycost of mfg. philosophy cost of materials movement cost of handling equipment

6. 10/13/2015IENG 471 Facilities Planning 6 Flow – Quantitative Equivalent Load Unit Accounts for volume and method Approximates cost (macro-level) ELUs become the unit of measure for flow between pairs of areas (dept.s) Flow is tracked on a square matrix Seek to minimize the sum of the flow volume and distance product for each pair of areas

7. 10/13/2015IENG 471 Facilities Planning 7 From – To Chart Similar to Map Mileage Charts: Matrix of Departments (Mfg. Cells) Cell entries quantify flow AND direction of flow between departments Steps to Create: List departments in OPC sequence From department is listed vertically To department is listed horizontally Establish Equivalent Load Unit measure DistanceQtyCost/Trip* Record flow volume in chart Above diagonal is forward flow Below diagonal is back-track flow

8. 10/13/2015IENG 471 Facilities Planning 8 Data Collection: From – To Chart Set up a spreadsheet with extra wide / tall cells Define ELU units between departments Could be different in each cell! Use tally marks to track trips Could scale for high trip counts Final tally is ELU trips per unit time

9. 10/13/2015IENG 471 Facilities Planning 9 From – To Chart: Flow Qty Order according to OPC flow Above diagonal is forward flow: From Dept. is on Left To Dept. is on top ELU volume (number of trips) is entered in the cell Below diagonal is back flow: Often rework / scrap

10. 10/13/2015IENG 471 Facilities Planning 10 Flow – Qualitative Closeness Ratings Accounts for info transfer & contact frequency and intangibles … Noise tolerance, control needs, aesthetics, security, dirt control, safety issues, etc. Rating Scale for closeness: A – absolutely necessary E – especially important I – important O – ordinary closeness OK U – unimportant to be close X – closeness is not desirable Examples: Machining Center for magnesium parts and: First aid station Raw materials supply for the center Fire suppression station Packaging (cardboard) storage Next workstation on Operations Process Chart if next operation is Assembly Inspection Liquid paint

11. 10/13/2015IENG 471 Facilities Planning 11 Relationship Chart Qualitative Flow Obtained from Interviews List departments Conduct interviews Define criteria Establish relationship value & reason for all pairs Review chart with ALL involved parties for evaluation & discussion

12. 10/13/2015IENG 471 Facilities Planning 12 Relationship Chart - Example

13. 10/13/2015IENG 471 Facilities Planning 13 Evaluating Flow Information

14. 10/13/2015IENG 471 Facilities Planning 14 Estimating Dept. Space Space must be allowed for the activities carried out in the departments Typical Information to capture for Equipment: Machine Data (manufacturer, type, model, s/n) Location of safety stops (big red buttons, …) Floor loading (weight of machine) Height, width, depth (static – non-operating) Maximum operating travel (up, left, right, back, fwd) Maintenance space and location (remove & repair) Plant service spaces and locations (utilities)

15. 10/13/2015IENG 471 Facilities Planning 15 Estimating Dept. Space Space must be allowed for the activities carried out in the departments Typical Information to capture for Materials: Receiving and In-bound storage Work In-Process Out-bound storage and Shipping Waste storage and Shipping Storage for unused tools, fixtures, jigs, … Storage for maintenance equipment

16. 10/13/2015IENG 471 Facilities Planning 16 Estimating Dept. Space Space must be allowed for the activities carried out in the departments Typical Information to capture for Operators: Operator while working Operator while resting Operator while handling material Operator while entering (ingress) and leaving (egress) Remember Ergonomic considerations!

17. 10/13/2015IENG 471 Facilities Planning 17 Space – Production Floor Personnel need space for: Operating equipment Dependent on operation Interview operators, observe similar cells Material Handling Dependent on material and sizes See Tables 3.3 & 3.4 (see next slide) from Bozier, et. al. Ingress & Egress Dependent on safety, equipment footprint: 30 inches between static objects 36 inches between static object & operating equipment 42 inches between two operating pieces of equipment

18. 10/13/2015IENG 471 Facilities Planning 18 Estimating Aisle Space Flow Analysis allows us to estimate space required for the materials going through the departments Also need to allow for space for moving materials moving between departments Typically, this is based on the size of the From department (footprint), the size (of load) and the method of movement (equipment size)

19. 10/13/2015IENG 471 Facilities Planning 19 Aisle Space Example Assume a reaction-injection molding (RIM) cell handling car bumpers: Cell dimension is 50 ft x 15 ft = 750 ft 2 Bumper size is 6 ft x 1 ft = 6 ft 2 Aisle is desired between two operating cells (lengthwise): Using Table 3.3: (15%)(750 ft 2 ) = 2.25 ft = 27 inches 50 ft But, subject to OSHA, use the 42 inch width between operating equipment!

20. 10/13/2015IENG 471 Facilities Planning 20 Aisle Space Example – Cont. Assume a RIM cell handling car bumpers – and a pallet of bumpers at the end of the cell that is moved by a pallet-jack (manual platform truck) Using Table 3.4:Aisle width is 5 ft = 60 inches OSHA Requirement:42 inches (worst case) – met! Bumper size is 6 ft x 1 ft:so increase to 6 ft = 72 inches But, the aisle is blocked while loading pallet, must allow for two-way flow of bumper pallets:so increase to 2 x 6 ft = 144 inches And then add some space for clearance!

21. 10/13/2015IENG 471 Facilities Planning 21 Questions & Issues