Unit 5
Manufacturing Facilities Design and
Analysis: Management and Applications of
Computer Simulation and Modeling
This Unit Focuses On:
1. The plot plan
2. Management
3. Applications of computer simulation and modeling
to facility parts flow, processing, analysis, and
management
4. Advantages of computer simulation and modeling to
facility parts flow, processing, analysis, and
management
Meyers & Stephens Chapter 14:
Facilities Design: The Layout
• The resulting layout is the visual presentation
of the data collected and analyzed by the
facilities planner.
• It must communicate the complex results of
months of data collection and analysis.
• It is only as good as the data backing it up.
Plot Plan
• A plot plan is an engineering diagram which
shows the equipment layout, the positions of
roads, buildings and other constructions inside an
industrial facility to a defined scale.
• In all cases the plot plan is a 'top down'
orientation.
Plot Plan Vs Group Project
•
Total amount of space anticipated for the proposed
plant (the sum of all calculated spaces for machines,
offices, storage, restrooms, shipping & receiving, isles,
tool room, cribs, cabinets, benches, assemblers,
conference rooms, lunch rooms, stock room etc.)
•
Show all your data and calculations in a work sheet.
Plot Plan Vs Group Project
• Your group should design an ideal layout of the
equipment, workstations, transportation, MHS, storage,
etc. necessary for complete production of your entire
products.
• The layout must be drawn to scale, dimensioned, in 2- or
3-D, and enclosed in a dimensioned facility.
• Show the basic framework of the facilities and the process
flow of only the parts assigned to you with different line
types or line colors indicating each student.
The Plot Plan:
• Shows how the buildings, parking lots and driveways fit on the
property
• Has 8 suggested steps to develop:
1. Start with a layout of the property showing the lot lines
2. Place in the layout the main roads that border the property or
where the access road will enter the property
3. Show sources of water, power, gas, and phones
4. Place the building where the front faces the road and the long
side faces the road
5. Show receiving and shipping
6. Connect receiving and shipping to the main road
7. Show where employee and public entrances will be located
8. Provide parking for visitors and employees
Item
Length
X
Width
Sq. Ft
X
No of Stations
Total Square Ft
Milling Machine
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Injection Molding Machine
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Paint Systems
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Puch Press
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Assembly
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Parking
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Stores
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Milling Machine
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Sawing machines
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Offices
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Lockers
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Assembly
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Parking
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Stores
XXXXXXXXXX
XXXXXXXXXX
XXXXXXXXXX
Total Square Feet
XXXXXXXXXX
Plant Layout Methods
• Template and tape technique
• Three-dimensional models technique
• Computer-aided design (CAD) technique
Master Plan
• Is the finished product of the facilities design
project
• Shows where every machine, workstation,
department, desk, and all other items are
located
• A scale of 1/4” = 1 ft or 1/8” = 1ft is
recommended
Obi, Chapter 12
Managing and Improving Manufacturing
Systems
Manufacturing Management (or
Control) Defined
• Checking current performance of a system against predetermined or set standards
• Seeing that tasks are being carried out according to set
plans.
• Measurement and correction of performance to ensure
that objectives and the plans devised to attain them are
accomplished.
• What are being managed or controlled are manufacturing
systems:
– Machines, tooling, equipment, facilities, production methods,
processes, procedures, quality assurance, production control,
materials, material moving and handling systems, people, and the
end products
Steps in Control
• Establishment of performance standards.
• Measuring the actual or realized performance.
• Comparing the measured performance against
the established standards.
• Taking corrective action as needed.
Some Areas of Management
People
Methods and
Processes
Manufacturing
Materials and
Material
Handling
Systems
Facilities and
Equipment
Products
Personnel Management
•
•
•
•
•
•
Seeking competent employees
Hiring competent employees
Training competent employees
Motivating employees
Evaluating employees
Rewarding employees
Personnel Management
Plant Manager
Milling
Supervisor
Turning
Supervisor
Ass./Box/Ship
Supervisor
Found/Fin.
Supervisor
Drill/Saw
Supervisor
Operator
Operator
Assemble
r
Molder
Operator
Operator
Operator
Assemble
r
Molder
Operator
Operator
Operator
Assemble
r
Molder
Operator
Operator
Operator
Assemble
r
Molder
Operator
Operator
Operator
Assemble
r
Molder
Operator
Operator
Operator
Boxer
Molder
Operator
Operator
Operator
Boxer
Finisher
Operator
Boxer
Finisher
Operator
Boxer
Finisher
Shipping
Finisher
Shipping
Shipping
Quality Control
•
•
•
•
•
Process control
Product characteristics
Design specifications
Customer needs and characteristics
Equipment utilization
Facility Management
• Building:
–
–
–
–
Energy
Safety
Scheduling
Maintenance
• Equipment:
– Maintenance
– Scheduling
– Arrangement
• Materials:
–
–
–
–
Scheduling
Storage
Quality
Quantity
Inventory Management
•
•
•
•
•
•
•
•
•
Materials
Machines
Tools
Tooling (jigs, molds, dies, punches etc)
Hardware (nuts, screws, washers etc)
Stationeries
Janitorial supplies
Software
Others
Supply Chain Management
• Is based on the idea that every product that reaches
the customer is a result of the efforts of many
organizations at various levels.
• These multi-level organizations are generally called
the supply chain.
• The management of the entire chain of activities is
known as supply chain management.
Supply Chain Management
Raw
Material
Supplier
Raw
Material
Supplier
Raw
Material
Supplier
Supplier’s
Supplier
(Tier 2)
Supplier’s
Supplier
(Tier 2)
Bicycle
Wholesaler
End
Customer
Aluminum
Bars
Bicycle
Wheels
Supplier
(Tier 1)
Retailer
Wholesale
r
Bicycle
Store
Retailer
End
Customer
Bauxite
End
Customer
Bicycle
Customer
Applications of Computer Simulation and Modeling
1. Simulation is defined as an experimental technique, usually
performed on a computer, to analyze the behavior of any real-world
operating system
2. Simulation can be used to predict the behavior of a complex
manufacturing or service system by actually tracking the movements
and the interaction of the system components
3. The simulation software generates reports and detailed statistics
describing the behavior of the system under study
4. The physical layouts, equipment selection, operating procedures,
resource allocation and utilization, inventory policies, and other
system characteristics can be evaluated based on these reports
Advantages of Simulation
• Flexible and straightforward
• Can be used for large and complex models
that may not lend themselves to mathematical
models
• Allows for study of the interactive effects of
many components in a dynamic and stochastic
environment
• Can be used to study alternative ideas
Disadvantages of Simulation
• Can be very expensive and time consuming
to develop
• Results may not be exactly what is needed
(garbage-in-garbage-out)
How Simulation Works
• The purpose of simulation is to help the
decision maker solve a particular problem
• There are 10 basic steps in simulation
Ten basic steps in simulation
1. Problem definition (clearly define problem
and state the goals)
2. System definition (define the boundaries
and restrictions of system in terms of
resource availability)
3. Conceptualize model (develop a graphical
model to define system components,
variables etc.)
4. Preliminary design (what data are needed?
in what form? etc.)
5. Input data preparation (gabage-in-gabageout)
Ten basic steps in simulation
(continued)
6. Model translation (develop working
knowledge of simulation package)
7. Verification and validation
8. Experimentation
9. Analysis and interpretation
10. Implementation and documentation
Uses of Simulation
•
•
•
•
•
•
For evaluation
For comparison
For prediction
For sensitivity analysis
For optimization
For bottleneck analysis
Some Simulation Packages
•
•
•
•
•
SIMPROCESS
ProModel
FactoryFLOW
FACTOR/AIM
ARENA
SIMPROCESS Steps
SIMPROCESS Hammer Example
SIMPROCESS Hammer Example
(Process Flow)
Hammer
Head
Task 1
Task 2
Task 3
Task 4
Task 5
Task 6
Task 7
Process
Face end of part
Turn outside
diameter
Form two groves
Form ball peen end
Balloon
Number
3
1
Time
0.5
0.75
Hammer
Handle
Task 1
Task 2
8&9
7
0.75
1.0
Task 3
Task 4
10
10
2
0.75
0.25
0.75
Task 5
Task 6
Task 7
4.75
Total
Time
Drill hole
Tap hole
Cut off finished
handle
Total
Time
Assembly
Process
Process
Face end of part
Turn diameter of
handle
Turn taper
Turn thread end of
handle
Thread end of handle
Knurl handle
Cut off finished handle
Time
17
12
0.75
1.0
11
15
13
0.75
0.5
0.75
0.5
0.75
5.0
Time
Task 1
Deburr head and handle
0.1
Task 2
Screw head to handle
0.5
Task 3
Cold-head end of hammer
1.5
Task 4
File and sand end of hammer
1.0
Task 5
Inspect finished hammer
0.5
Total Time
Balloon
Number
14
16
4.5
SIMPROCESS Hammer Layout
Example
SIMPROCESS Simulation Example
SIMPROCESS Tool Pallet
SIMPROCESS Hammer Results
______________________________________________________________________
Type of resource
% Utilization
______________________________________________________________________
CNC lathe for hammer head
50
CNC lathe for hammer handle
49
CNC lathe operator
99.99
Heading machine
97.84
Hammer assembler
54.44
__________________________________________________________________
Simulation Practice Exercises
To Be Assigned