1.
II CONCURRENT ENGINEERING
OF PRODUCT, PROCESS,
SCHEDULE & FACILITIES
Concurrent Engineering &
Systems Approach
• Concurrency implies different systems and engineering
functions performed at the same time in a consistent
manner
• Facilities engineering is not a stand-alone process -- highly
dependent on what, how, when & how much to produce.
• What? = Products
By
Rakesh Nagi
• How? = Process
Department of Industrial Engineering
SUNY at Buffalo
• When? = Production scheduling
• How much? = Production planning, forecasting
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State University of New York at Buffalo
Department of Industrial Engineering
Product, Process & Schedule
Interaction With Facilities Design
2.
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Department of Industrial Engineering
Product Design
• Functions
Product
Design
• Dimensions and shape
• Materials
Facilities
Design
Schedule
Process
Design
Design
• Quality and aesthetics
The product design is then described in:
• Engineering drawings: specify materials,
dimensions, quality, assembly structure
SYSTEMS APPROACH
Consistent & coordinated functioning of various
functions
State University of New York at Buffalo
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2.
– Multiview drawing: third angle projection
– Perspective drawing
State University of New York at Buffalo
Department of Industrial Engineering
– Assembly drawing
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Department of Industrial Engineering
Product Design
2.
Product Design
• Parts list: Name, Descr., Drw. #, Quantity req.,
Material, Size, Vendor
• Parts list: Name, Descr., Drw. # , Quantity req.,
Material, Size, Vendor
• Bills-Of-Materials (BOM): Assembly structure Matl. Req.
• Bills-Of-Materials (BOM): Assembly structure Matl. Req.
Table
1 week
Top (1)
2 weeks
Leg Assem (1)
1 week
Legs (4)
3 weeks
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State University of New York at Buffalo
Department of Industrial Engineering
Page 1
Frame (1)
1 week
State University of New York at Buffalo
Department of Industrial Engineering
3.
3.
Process Design
Process Design
• Process selection
• Make-or-buy decisions -- break even analysis
–
–
–
–
C=px
C=K+mx
Define elemental operations from product design
Identify alternative operations for each operation
Analyze alternatives -- depends on production quantity
Standardize process
• Process sequencing
K
– Route sheet or routing (fig. 3.10, pp. 44-45)
– Assembly chart (fig. 3.11, P. 46)
– Operation process chart (fig. 3.12, p. 47) -- Combines above
Break-even point
Number of units (x)
• Computer-Aided Process Planning (CAPP)
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3.
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State University of New York at Buffalo
Department of Industrial Engineering
Process Design
4.
Schedule Design
• How much to produce at a time (lot sizing)
• Process selection
–
–
–
–
State University of New York at Buffalo
Department of Industrial Engineering
• How long to produce
Define elemental operations from product design
Identify alternative operations for each operation
Analyze alternatives -- depends on production quantity
Standardize process
• When to produce (scheduling)
4.1 Market information
• Less specific information => general design
• Process sequencing
• More specific information => optimized design
– Route sheet or routing (fig. 3.10, pp. 44-45)
– Assembly chart (fig. 3.11, P. 46)
– Operation process chart (fig. 3.12, p. 47) -- Combines above
• Volume, trend and life
• Computer-Aided Process Planning (CAPP)
CAD
CAPP
4.
CAM
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State University of New York at Buffalo
Department of Industrial Engineering
Schedule Design
4.
State University of New York at Buffalo
Department of Industrial Engineering
Schedule Design
• How much to produce at a time (lot sizing)
• How long to produce
• Uncertainty: most likely, optimistic, pessimistic
• When to produce (scheduling)
• Qualitative information (Table 3.4, p. 53)
4.1 Market information
• Less specific information => general design
4.2 PARETO ANALYSIS
• More specific information => optimized design
• Variety vs. Volume (P-Q) analysis
• Volume, trend and life
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State University of New York at Buffalo
Department of Industrial Engineering
Page 2
State University of New York at Buffalo
Department of Industrial Engineering
4.
5. Production Quantity &
Equipment Requirement
Schedule Design
• Uncertainty: most likely, optimistic, pessimistic
DETERMINING CAPACITY REQUIREMENTS
• Qualitative information (Table 3.4, p. 53)
• Quantity requirements
workload)
4.2 PARETO ANALYSIS
• X = D [ I - B ]-1, D = end-item demand vector, X = prod.
State University of New York at Buffalo
reqmnts.
15%
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State University of New York at Buffalo
Department of Industrial Engineering
5. Production Quantity &
Equipment Requirement
C (1)
5.2 DETERMINING INPUT REQUIREMENTS
CONSIDERING SCRAP
• Definitions
– Pk : percentage of scrap produced on k-th operation
– Ok : desired non-defective output from k-th operation
– Ik : input requirement to k-th operation
BOM M atrix
B(2)
D(2)
A
0
0
0
0
0
B
2
0
0
0
0
C
1
0
0
0
0
D
0
2
0
0
0
E
0
3
0
0
0
1
-1 0
(I - B) = 0
0
0
2
1
0
0
0
1
0
1
0
0
4
2
0
1
0
6
3
0
0
1
E(3)
Ik
D = (100, 0, 5, 10, 15) ; X = (100, 0, 5, 10, 15)(I - B)-1
= (100, 200, 105, 410, 615)
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– Equip. Fraction = (Total time for operation) / (Total time available)
– Total time reqd. = setup time × # of setups + run time × # of opns.
– Reliability Factor (m/c efficiency) = uptime/(uptime + downtime)
• DETERMINISTIC MODEL
total time reqd.
capacity per × efficiency ×
K-th
operation
O k = Ik+1
PkI k
(K+1)-th
operation
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State University of New York at Buffalo
Department of Industrial Engineering
5.3 DETERMINING EQUIPMENT REQUIREMENTS
INDIVIDUAL EQUIPMENT REQUIREMENTS
• EQUIPMENT FRACTION: proportion of equipment
reqd. for an op.
# of machines required =
Department of Industrial Engineering
5. Production Quantity &
Equipment Requirement
5.1 DETERMINING QUANTITY REQUIREMENTS
A
B
C
D
E
=>
• BOM matrix,B = [bij], bij = # of item j required for 1
unit item i
job shop arrangement
(process layout)
A
time
5.1 DETERMINING QUANTITY REQUIREMENTS
mass production arrangement
(product layout)
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processing
• Equipment requirements
• Variety vs. Volume (P-Q) analysis
85%
(&
performance
• PROBABILISTIC MODEL
OVERALL EQUIPMENT REQUIREMENTS
• combine equipment factors for identical equipment type
• consider overtime and subcontracting
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Page 3
State University of New York at Buffalo
Department of Industrial Engineering