SUBJECT
 Industrial facility design
GROUP MEMBERS
• H.Hammad Ali
• S.Hammad shah
• Hammad Hassan
11-IE-32
11-IE-21
11-IE-41
Introduction
• Facility Planning:
The process of identifying the needs of facility users in order to
create a project design that meets those needs.
Facility plan Process
• Facility planning process for manufacturing and assemble
the products.
 Define the Product
Specify the required Manufacturing
Determine the interrelationship
Determine the space requirements
Generate the alternative FP
Evaluate the FP
Implement the FP
Maintain and adapt the FP
Update the products
Alternative Facility Plan
• Facilities can be broadly defined as buildings where people,
material, and machines .... Evaluate alternative facilities
plans (alternative locations and alternative).
• Before the alternative facility plan answered the some
questions.
What is to be produced?
How are the products to be produced?
When are the products to be produced?
How much each product to be produced?
How long the products to be produced?
Where are the products to be produced?
Global Sourcing
• A procurement strategy in which a business seeks to find the
most cost efficient location for manufacturing a product even
if the location is in a foreign country.
• Examples
An Automobile Industry
An toy Industry
Textile Industry
PP&S Design
Product Design
Process Design
Schedule Design
Product Design
Both the Determination
Decision and Upper level management
Dynamic Product Environment
In Which it is not possible to accurately specify the products
to be produced in a given facility.
Design of the Product
The design of the product is influenced by aesthetic, material
……
Meet the needs of the costumer.
Quality Function Deployment
Organized planning approach
To identify customer needs
To translate needs of product charactaristics,product design
and tolerance requirements.
Benchmarking
What the Competition is doing to satisfy the customer needs.
Exceeds customer expectations
Exploded Assembly Drawing
An exploded view drawing is a diagram, picture or technical
drawing of an object, that shows the relationship or order of
assembly of various parts.
Computer Aided Design
Computer-aided design (CAD) is the use of computer systems
to assist in the creation, modification, analysis, or optimization
of a design.
Concurrent Engineering
To improve relationship b/w the function of the component or
product and its cost.
Concurrent engineering provides a simultaneous
consideration in the design face of cycle factor such as
product, function, material, design, manufacturing and quality.
Example #2.1
• Calculating the production requirements for a serial process
with three operations
• A product has a market estimate of 97000 Requires three
processing steps (drilling, milling, turning ) having defective
estimates.
• D1=0.04
• D2=0.01
• D3=0.03
• Find the Inputs?
• Using Formula
• Ok=Ik-dk
Process design
How product
is produced?
Time
required?
Process
design
Equipment?
Manufacture
or Buy?
Steps in process design
• Identify required process
• Selecting the required process
• Sequencing the required process
Identifying required process
• Determine the scope of facility.
• Downsize large facilities.
• Make or buy decision should take input from:
- Finance, marketing, industrial engineering, process,
purchasing, HR and others.
• List the items
that needs to
buy or
manufacture
on a bill of
material.
• While making a bill of materials, in addition to make-or-buy
decision, parts list atleast include the following
- Part number
- Part names
- Number of parts per product
- Drawing references
Selecting the required process
• Make-or-buy decisions are based on
- previous experiences
- related requirements
- available equipments
- production rates
Bill of material for an Air flow regulator
Process Identification:
• It consists of description of what is to be accomplished, what
is to be manufactured, part drawings describing each
component, quantities to be produced.
Computer aided process planning:
• Can be used to automate the manual process planning.
Types of CAPP:
Variant
• Standard process plans for each part and stored
within computer. It is less expensive and easy.
Generative
• Process plans are generated automatically for
new components without requiring existing
plans.
Steps in process selection:
•
•
•
•
•
•
Define elemental operations
Identify alternative processes for each operation
Analyze alternative processes
Standardize process
Evaluate alternative process
Select process
Sequencing the required process
Assembly chart:
• Document the method of assembling the product.
• The easiest method to construct is to begin with completed
product and to trace disassembly back to its basic
components.
Assembly chart
Operations Chart
• To construct, begin with the upper right side of chart with
components as first assembly operations.
• It can be complemented with transportation, storages and
delays.
• It gives an overview of the flow within the facility.
Precedence diagram
• Operation chart as a special case of more general graphical
model is called precedence diagram.
• It establishes the precedence relationships that must be
maintained in manufacturing and assembling a product.
Group technology
• GT refers to grouping part into families, and then making
design decisions.
• It is based on part shapes, sizes, material type and
characteristics.
Schedule design
How much
to
produce?
When to
produce?
How long
production will
continue?
• Schedule design decision impacts on
- machine selection
- number of machines
- number of employees
- space requirements
- storage equipment
- material handling equipment etc
Marketing information
• It determines how long the production will continue.
• It is the information regarding the dynamic value of a
demand of product.
Pareto analysis
• Pareto, observed that 85% wealth of the world is held by 15%
of the people.
• It is depicted in volume-variety chart.
• It suggests that facility plan should consist of mass
production for the 15% of high volume items.
Specifications of Process requirements typically occurs in
three phases,
• 1st Phase : Determines quantity that must be produced
• 2nd Phase : Machine requirement
• 3rd phase : combines the operation requirements to
overall machine requirements
Calculations of Production
Requirements
• Let dk represents the percentage of defects produced in kth
operation
• Ok Desired output without defects
• Ik production Input
Ok = Ik – Defectives
Defective Parts = Ik × dk
Ok = Ik – dkIk
= Ik(1-dk)
• Once the product, process & schedule design decisions have been
made the facility planner needs to organize the information and
generate and evaluate layout, handling, storage and unit load
design alternatives.
1.
2.
3.
4.
5.
6.
7.
Affinity Diagram
Interrelationship Digraph
Tree Diagram
Matrix Diagram
Contingency diagram
Activity Network Diagram
Prioritization Matrix
• Gather verbal data & organize it in groups
Affinity Diagram
Form Product
Families
Assign Families to
manufacturing Cell
Assign Raw
material to their
point of use
Keep receiving &
shipping close to
Production
• The tree diagram is used to map the increasing detail the action
that need to be accomplished in order to achieve the objective.
• It organizes information such as characteristics, functions and
tasks into set of items to be compared.
• This tool provides visibility to key contacts to specific issues
and help to identify individuals who are assigned to too many
teams.
Team /
Participants
Joe
Mary
Part Usage Team
P
Machine use team
L
Jerry
C
Demand Forecast
Team
P
Anna
Daisy
L
Jack
P
C
P
P
L=Team Leader
C=Team Coordinator
P=Team Participant
Linda
C
L
Contingency Diagram
• Also Known as process decision program chart.
• It maps conceivable events & contingencies that might occur
during Implementation.
• It’s useful when project consists of Unfamiliar tasks.
Contingency Diagram
•
•
•
•
Used to develop a work schedule for the facilities design.
CPM (Critical Path Method)
Gantt Chart
PERT (Program evaluation & Review Technique)
Prioritization Matrix
In Facility Design it is important to consider:
• Layout characteristics
• Material Handling Requirements
• Unit load Implied
• Storage strategies
• Over all Building Impact