Products and Facilities
Methods, Standards, and Work Design
11th Edition
Niebel/Freivalds
1
Concurrent Engineering
Defined

Concurrent engineering
– the simultaneous development of project design
functions
– open and interactive communication existing
among all team members for the purposes of:
» reducing time to market,
» decreasing cost, and
» improving quality and reliability
2
Design for Manufacturing and Assembly

Greatest improvements related to DFMA
arise from simplification of the product by
reducing the number of separate parts:
» 1. During the operation of the product, does the
part move relative to all other parts already
assembled?
» 2. Must the part be of a different material or be
isolated from other parts already assembled?
» 3. Must the part be separate from all other parts to
allow the disassembly of the product for
adjustment or maintenance?
3
Types of Processes

Conversion - changing iron ore into steel

Fabrication - making car bumpers from
plastic

Assembly - assembling a car

Testing - computer boards - not a
fundamental process
4
Process Flow Structures




Job shop - small batches of a large number of different
products
– printing, machine shop, tool & die
Batch shop - standardized job shop, products
produced in batches
– clothing
Assembly Line - parts move from station to station at a
controlled rate
– microwaves, cars
Continuous Flow - continuous versus discrete flow
– beer, paint
5
Exhibit 5.10
Low
Volume,
One of a
Kind
I.
Job
Shop
II.
Batch
III.
Assembly
Line
IV.
Continuous
Flow
Few
High
Multiple
Major
Volume,
Products, Products,
High
Low
Higher StandardVolume Volume
ization
Flexibility (High)
Unit Cost (High)
Commercial
Printer
French Restaurant
Heavy
Equipment
Coffee Shop
Automobile
Assembly
Burger King
Sugar
Refinery
Flexibility (Low)
Unit Cost (Low)
6
Basic Production Layout Formats

Process Layout

Product Layout

Group Technology (Cellular) Layout

Fixed-Position Layout
7
Flow Through Systems
8
Process-Oriented Layout


Design places departments with large flows
of material or people together
Dept. areas have similar processes
– e.g., All x-ray machines in same area


Used with process-focused processes
Examples
– Hospitals
– Machine shops
© 1995 Corel Corp.
9
Process-Oriented Layout
Floor Plan
Table Saws
Office
© 1995
Corel Corp.
Drill Presses
Tool Room
© 1995 Corel Corp.
10
Product-Oriented Layout


Facility organized around product
Design minimizes line imbalance
– Delay between work stations


Types: Fabrication line; assembly line
Examples
– Auto assembly line
– Brewery
– Paper mfg.
© 1984-1994 T/Maker Co.
11
Product-Oriented Layout Floor Plan
1
3
4
Operations
5
2
Belt
Conveyor
Office
12
Cellular Layout - Group Technology
(Work Cells)



Special case of process-oriented layout
Consists of different machines brought
together to make a product
Group Technology Benefits:
– Better human relations
– Improved operator expertise
– Less in-process inventory and material handling
– Faster production setup
13
Work Cell Floor Plan
Saws
Tool Room
Drills
Office
Work Cell
14
Fixed-Position Layout



Design is for stationary project
Workers & equipment come to site
Complicating factors
– Limited space at site
– Changing material needs

© 1995
Corel Corp.
Examples
– Ship building
– Highway construction
© 1995
Corel Corp.
© 1995 Corel Corp.
15
Fixed Position Layout
Question: What are our primary considerations for a
fixed position layout?
Answer: Arranging materials and equipment
concentrically around the production point in their
order of use.
16