Facilities Quiz 1

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AREAS OF INTEREST:

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Transportation

ReceivingStorageProductionAssemblyPackaging and packingMaterial handling Personnel services

Auxiliary production services- (giving assistance or support)WarehousingShippingOfficesExternal FacilitiesBuildingsGroundsLocationSafetyScrap

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The work of designing a facility usually starts with an analysis

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The product to be made or service to be performedConsideration of the overall flow of material or activity

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Importance of facilities design

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An efficient plan for the flow of materialsThe material flow patternMaterial handling

Effective arrangement of facilities around the material flow patternEfficient operation of the processes Minimum production cost should result in maximum profit.

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Objectives of facilities design

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Facilitate the manufacturing processMinimize material handlingMaintain flexibility of arrangement and operationMaintain high turn over of work in processHold down investment in equipmentMake economical use of building cubePromote effective utilization of man powerProvide for employee convenience, safety, and comfort in doing the work.

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Facilitating the manufacturing processsuggestions

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Arrange machines, equipment, and work areas

Eliminate all delays possible

Plan the flow

Maintain quality of work by planning

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Promoting effective use of manpower

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1. Reduce manual handling of materials to a minimum2. Minimizing walking3. Balance machine cycles4. Provide for effective supervision

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is a primary requisite for economical production

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An efficient plan for the flow of materials

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becomes the basis for an effective arrangement of physical facilities

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The material flow pattern

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converts the static flow pattern into a dynamic reality , providing means by which material is caused or permitted to flow

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Material handling –

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Lay out Planning

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Involves decisions about the physical arrangement of economic activity centers within a facility. M

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Goal of layout planning

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Is to allow workers and equipment to operate at peak effectiveness and efficiency.

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Four questions in lay out planning

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What centers should the lay out include?How much space and capacity does each center need?How should each center’s space be configured?Where should each center be located?

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facilitates the flow of materials and more efficient utilization of labor and equipment.

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Proper lay out

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Lay out choices

Plan for current or future needs ;

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Whether to select a single-story or multiple – story designWhether to open up the planning process to employee suggestionsWhat type of lay out to choose What performance criteria to emphasize

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When positioning strategy calls for low-volume ,high-variety production, such as in a job shop , the operations manager must organize resources around the process.

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Process lay out

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a strategy that when a facility’s positioning strategy calls for repetitive or continuous production, the operations manager dedicates resources to individual products or tasks.

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product lay out

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When a positioning strategy combines elements of both a product and process focus.

This intermediate strategy calls for a, which arranges some portions of the facility as a process lay out and others as a product lay out.

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hybrid lay out

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When the product is particularly massive or difficult to move (ex. Assembling locomotives , making huge pressure vessels , building dams , or repairing home furnaces )______ is only the feasible solution.

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a fixed-position lay out

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is most common when the same operation must intermittently produce many different products or serve many different customers.

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process lay out

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Advantages of process lay out

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It is more flexibleEquipment utilization is high Employee supervision can be specialized

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Disadvantages of process lay out

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Processing rates tend to be slowerProductive time is lost in changing from one product or service to another.More space and capital are tied up in inventoryThe time lags between job starts and end points are relatively longMaterials handling tends to be costly

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Arranges work stations or departments in a linear path.

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Product layout

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often called production or assembly line

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Product layout

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often called production or assembly line

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Product layout

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Disadvantages of product layout

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Product lay outs often rely heavily on specialized, capital-intensive resources. These lay outs are therefore riskier for products or services with short or uncertain lives.

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Advantages pf product layout

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Faster processing ratesLower inventoriesLess unproductive time lost to changeover

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Combines elements of both a product and process focus.Arranges some portions of the facility as a process lay out and others as a product lay out.

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Hybrid layout

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Fms

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flexible manufacturing systems

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GT

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Group Technology

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OWMM

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one worker ; multiple machines

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This manufacturing technique groups parts or products with similar characteristics into families and sets aside groups of machines for their production.

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Group Technology

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The goal is to find a set of products with similar processing requirements and minimize machine changeover or set up.

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Group Technology

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Organize the machine tools needed to perform the basic processes into separate areas called

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Cell

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Benefits of Gt

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Less set up timeLower work-in-process inventoryLess materials handlingReduced cycle timeIncreased opportunities for automation

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A process in which a worker operates several different machines simultaneously to achieve a line flow. There are several different machines in the line

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One worker, multiple machine (OWMM)

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(OWMM)

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One worker, multiple machine (OWMM)

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machines included in OWMM

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automatic tool changers, loaders and un loaders, start and stop devices, and fail-safe devices that detect defective parts or products.

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Is a configuration of computer-controlled , semi-independent work stations where materials are automatically handled and machine loaded.

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Flexible manufacturing systems

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a type of flexible automation and is part of CIM.

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FMS

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This type of lay out makes sense when the product is particularly massive or difficult to move

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Fixed –position lay out

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It minimizes the number of times that the product must be moved and often is the only feasible solution

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Fixed –position lay out

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means either that the facility remains desirable after significant changes occur or that it can be easily adapted in response to them.

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Layout flexibility

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Common reasons for redesign of lay outs:

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Inefficient operations (e.g. high cost, bottlenecks)Accidents or safety hazards.Changes in the design of products or services.Introduction of new products or services.Changes in the volume of output or mix outputs.Changes in methods or equipmentChanges in environment or other legal requirements.Morale problems (e.g. lack of face-to-face- contact

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THREE BASICS STEPSdeisgning process layout

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1.Gather information2.Develop a block plan3.Design a detailed lay-out

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Itemizes the specific equipment and space needed for each center, then adds enough circulation space to provide for aisles and the like. Circulation space may consume _______ of the center’s total space.

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at least 25 percent

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is a rough space allocation for each department and indicates its placement.

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Block plan