Models for the Production System 8/24/04 Paul A. Jensen Operations Research Models and Methods Copyright 2004 - All rights reserved What this course will do: Provide an understanding of problems and issues in manufacturing design Build flow models embodying the components of the manufacturing process Use operations research tools to analyze models and make decisions Identify waste in the manufacturing process Use models to quantify waste Use models for decisions to alleviate waste 2 R1 The production system may be very complex R2 R3 M1 M1 M1 M1 M1 M2 M1 M1 M3 M1 M1 M4 M5 M6 M7 M1 M1 M5 M1 M2 M3 M4 Of f ices V M1 M1 M6 Ope rations M achine s Re source s Raw M ate rials 3 Many design issues arise for the production system Business Design Schedule Design Product Design Distribution Design Service System Design Process Design Machine Design Production System Design Control System Design Facility Design 4 The process is described by its operations R1 R2 R3 R3 R2 R1 5 6 3 1 2 7 4 8 A 5 Alternative process designs with the same operations R3 R1 R2 5 R3 3 1 2 1 R2 3 Production Line Parallel Processing 6 2 4 R1 5 7 4 6 7 8 8 6 The process model admits greater detail R1 R3 R2 11 5 1 12 6 2 Sequence/Volume of Demand Operation/Process/ Machine 3 13 7 4 14 8 15 9 16 10 17 18 19 20 Transportation/ Facility Layout/ Material Handling Inspection/ Quality Control Delays/ Production Control/ System Design Storage/ Inventory Control/ Production Control 7 Numerical parameters describe components Operation O1 + P1 + (operation time, loss, M1) Transportation + O1 M1 Material Handling (time, distance, cost) Inspection I1 Quality Control (Standard Time, Proportion removed ) O1 8 Operations Involving Waiting Delays System Design + Production Control (Mean Delay, Standard Deviation) Storage System Design + Inventory Control (Safety Stock, Value, Turnover) 9 The models must describe multiple products Product A R1 Product B R1 R3 R2 Product C 4 1 1 5 2 2 6 3 3 A 4 R2 8 R3 4 1 2 9 5 3 A 10 7 6 VB 8 11 VA 7 A 12 13 VC 10 Our Goal: Build models to answer significant design questions Use operations research tools to provide assistance to decision makers 11 For Homework Table manufacture problem Identify some simple process Construct an operations process chart Give estimates of the important parameters for each operation defined 12