Facility Design – Week 2
Product, Process and
Equipment Design and Analysis
By
Anastasia Lidya Maukar
Data required for developing good layouts
• Product Analysis
• Process Analysis
2
Product Analysis
• Product analysis is to determine the product process
sequence
• The information about the product can be generated
from:
– Photograph
– Bill of Material
– Engineering Drawing
– Assembly Chart
– Route Sheet
– Operation Process
Chart
3
Gate Valve
4
Exploded Drawing of the Gate Valve
5
Engineering Drawing
• The part list includes the following information for each
piece required for the final assembly:
–
–
–
–
–
–
–
–
–
piece number
piece name
quantity required for the final assembly
material
stock size of the raw material
if needed
detail drawing numbers
weight
any other pertinent details
6
Engineering Drawing of the Gate Valve
Provide part
specifications and
dimensions in
sufficient detail for
manufacturing
7
Parts List of the Gate Valve
The parts list provides a
listing of the component
parts of a product. In
addition to make or buy
decisions, a parts list
includes part number,
part name, number of
parts per product, and
drawing references
8
Bill of Material
• A bill of material displays a list of parts and are directly
required to make a complete assembly.
• At minimum it should indicate, for each part
–
–
–
–
its number (or drawing number)
its description
the quantity necessary in the assembly
the part is to be made or buy
• The listing may include additional information such as:
– material description
– weight
– unit price
9
Bill of Materials for the Gate Valve
10
Bill of Material
•
Product — An item sold directly to customers (products
are listed in the Company catalog).
•
Assembly - A part that is made of two or more other parts
and associated labor. The parts, in turn, may be other
assemblies, components, materials or products.
•
Component - A part that is made on the shop floor (also
defined as material on which labor has been
performed). Some companies use the terms Assemblies
and Components interchangeably in their discussions of
Bills of Material structure. Defining them separately is
preferable.
•
Material - The type and size of raw material from which a
part is made, such as 3/4x48x120 particle board or 6-inch
brass railing, or a purchased part. Material is always
purchased.
11
Assembly Chart I
An assembly chart gives a broad
overview of how several parts
manufactured separately are to be
assembled to make the final product.
It is an analog model of the assembly
process. Circles with a single link
denote basic components, circles with
several links denote assembly
operations/subassemblies, and
squares represent inspection
operations.
12
Assembly Chart II
13
Route Sheet
• A route sheet specifies the operations required for a
part as well as the sequence of the machines visited for
these operations.
• It may also provide the set-up time for each machine,
processing time and labor time.
• It shows how a part is to be produced, which machine
are needed, the tools to use, estimated setup times for
the machines and production in terms for the machines
and production in terms of the number of units expected
per hour from each machine.
• One routing sheet is required for each part in the
assembly.
14
Route Sheet for one Component of the Gate Valve
Route sheet summarizes
whether a part will be
purchased or produced,
how the production of a
part will be achieved,
what equipment will be
used, and how long it
take to perform each
operation.
15
Operations Process Chart
By superimposing the route sheets and
the assembly chart, a chart results that
gives an overview of the flow within the
facility. This chart is the operations
process chart.
16
Precedence Diagram for Assembling the Gate Valve
A precedence diagram establishes the prerequisite assembly steps that must be
completed before performing a given assembly step.
17
Process Design & Analysis
• It is a design or analysis of how a product and its
componets are produced.The information consists of:
1. Operation sequence of each product/part (included make or
buy analysis for each part)
2. Machine, equipment, tools, fixtures, etc.
3. Operation sequence of assemblies and packout.
4. Standard time for each work element.
18
Process Design & Analysis
5. Determining the conveyor rate, assembly and packout lines
and painting/finishing system
6. Line balancing for each assembly and packout lines.
7. Load work cells.
8. Developing of workstation drawing for each operation using
motion economy and ergonomics.
19
Make-Or-Buy Decisions
1. Cost
2. Capacity
3. Quality
4. Speed
5. Reliability
6. Expertise
20
Make-or-Buy
• Reasons to make
– Cheaper to make
– Company has experience making it
– Idle production capacity available
– Compatibility and fit with company’s planned lines of business
– Part is proprietary
– Wish to avoid dependency an outside supplier
– Part fragility requiring high packing and transportation Costs
– Transportation costs are high
21
Make-or-Buy
• Reasons to buy
– Cheaper to buy
– Production facilities are unavailable
– Avoid fluctuating or seasonal demand
– Inexperience with manufacturing process
– Existence and availability of suppliers
– Maintain existing supplier relationship
– Higher reliability and quality
22
Machine & Equipment Selection
• The Number of Machines Needed? These questions
can be answered when we know:
– How many finished goods are needed per day?
– Which machine runs what parts?
– What is the time standard for each operation?
23
Machine & Equipment Selection
• Advantage:
– Make efficient use of capital equipment purchase budget
– Make efficient use of maintenance and operating budget
– Increase machine utilization
– Make efficient use of available space
24
Calculation of Number of Machine
t. p
NM 
 .
p = production rates(units/day)
η = machine efficiency
DT  S T
  1
D
τ = working hours per day(hours)
t = operation time(hours)
Using Backward Analysis (for the sequencing production processws) and each process
has a certain scrap, number of production unit to fulfill the demand :
N ol
N il 
1  Sl
Sl = % scrap pf process l
Nil = number of input for process l
Nol = number of output for process l
25
Calculation of machine requirements
INPUT
Nil
P1
P2
P3
1
2
3
1
Nol
OUTPUT
Nil = Nol + Scrap
Scrap
26
Personnel Requirement Analysis
n
N 
i 1
Ti .Oi
 .H
N = number of types of operations
Oi = aggregate number of operations of type i required on all the
pseudo/real products manufactured per day
Ti = standard time for an average operation Oi
H = total production time available per day
η = assumed production efficiency of the plant
27
Space Requirement & Availability
• Space for facilities
• Space for operator movement, loading & unloading
parts
• Space for incoming material & WIP
• Space for auxiliary equipment
• Space for future expansion and growth
28
Production space requirement sheet
Departme
nt Name
Work
Center
Name
Work
Center
Code
Lengt
h
(feet)
Width
(feet)
Area
(feet2 )
Auxiliar
y Area
(feet 2)
Operato
r Space
(feet2 )
Materia
l Space
(feet 2)
SubTotal
(feet2 )
Allowanc
e (feet2)
Total
space per
machine
(feet2 )
Number
of
Machine
s
Total
Space
Machine
Type
(feet2 )
General
Machining
Vertical
Milling
1202
15
15
225
70
30
50
375
150%
565
2
1130
Planer
2005L
25
5
125
40
20
40
225
125%
290
1
290
Punch
Press
3058
10
10
100
30
20
20
170
140%
240
2
480
Injection
Molding
6078
20
10
200
60
50
100
410
150%
615
3
1845
NCMachine
9087
20
8
160
50
30
30
270
125%
340
2
680
Lathe
1212
15
8
120
40
20
30
210
150%
315
1
315
AutoChucker
2056
5
5
25
10
5
5
45
125%
60
1
60
Otoscope
Cell
29