Introduction to Manufacturing Facilities Design and Material Handling - PowerPoint PPT Presentation

1 / 13
About This Presentation
Title:

Introduction to Manufacturing Facilities Design and Material Handling

Description:

Chapter 1 Introduction to Manufacturing Facilities Design and Material Handling Objectives After reading the chapter and reviewing the materials presented the ... – PowerPoint PPT presentation

Number of Views:948
Avg rating:3.0/5.0
Slides: 14
Provided by: generalUt4
Category:

less

Transcript and Presenter's Notes

Title: Introduction to Manufacturing Facilities Design and Material Handling


1
Chapter 1
  • Introduction to Manufacturing Facilities Design
    and Material Handling

2
Objectives
  • After reading the chapter and reviewing the
    materials presented the students will be able
    to
  • Understand the importance of a systematic
    approach to facilities planning
  • Identify the various types of waste
  • Understand systematic layout procedure

3
The Importance of Manufacturing Facilities Design
and Material Handling
  • The selection of the location may be influenced
    by economic factors such as tax incentives, low
    cost land, or relaxed environmental regulations.
  • Factors that may influence location strategy may
    include raw materials, energy, human resources
    and lower labor costs.
  • Facilities design includes plant location,
    building design, plant layout, and material
    handling systems.
  • Manufacturing facilities design is the
    organization of the companys physical assets to
    promote the efficient use resources such as
    people, material, equipment, and energy.
  • Building design is an architectural job, thus the
    architectural firms expertise in building design
    and construction techniques is extremely
    important to the facilities design project.
  • Layout is the physical arrangement of production
    machines and equipment, workstations, people,
    location of materials of all kinds and stages,
    and material handling equipment.
  • Material handling is simply defined as moving
    material. Material handling accounts for about
    50 of all industrial injuries and from 40 to 80
    of all operating costs.

4
The Importance of Manufacturing Facilities Design
and Material Handling
  • Facilities planners ask the six questions ( why,
    who, what, where, when, and how) about everything
    that can happen to a part flowing through a
    manufacturing facility (operation,
    transportation, inspection, storage, and delay)
    to eliminate steps, combine steps, change
    sequence of steps or simplify.
  • The five Ss principles are 1. Sifting
    (organization). Keeping the minimum of what is
    required will save space, inventory, and money.
    2. Sorting (arrangement). Everything has a
    specific place, and everything in its place is a
    visual management philosophy that affects
    facilities layout. 3. Sweeping (cleaning). A
    clean plant is a result of a facility layout that
    has been thought to provide room for everything.
    4. Spic and Span (hygiene). A safe plant is a
    result of good layout planning. 5. Strict
    (discipline). Following the procedures and
    standardized methods and making them a habit will
    keep the plant operating efficiently and safely.
  • The five whys will ensure that the solution to a
    problem is not a symptom of the problem, but
    rather, the base cause (page 4).

5
Lean Thinking and Lean Manufacturing
  • Lean manufacturing is a concept whereby all
    production people work together to eliminate
    waste.
  • Muda (waste) is defined as any expense that does
    not help produce value.
  • There are 8 kinds of muda overproduction,
    waiting, transportation, processing, inventory,
    motion, rework, and poor people utilization.
  • Kaizen is the Japanese word for continuous
    improvement. Every person in the company is
    encouraged to search for new ideas and
    opportunities to further improve the organization
    and its processes including reducing waste.
  • Kanban is a signal board that communicates the
    need for material and visually tells the operator
    to produce another unit or quantity. With pull
    systems parts are produced only when the need
    arises and they have been requested or there is a
    pull from production operations.
  • Value stream mapping (VSM) is the process of
    assessment of each component or the step of
    production to determine the extent to which it
    contributes to operational efficiency or product
    quality. VSM can reduce or eliminate excessive
    material handling, eliminate wasted space, create
    a better control of all types of inventory and
    streamline various production steps.

6
The Goals of Manufacturing Facilities Design and
Material Handling
  • A mission statement communicates the primary
    goals and the culture of the organization to the
    facilities planner.
  • 1. Minimize unit and project costs It does not
    mean buying the cheapest machine, because the
    most expensive machine may produce the lowest
    unit cost.
  • 2. Optimize quality Quality and cost are the two
    primary competitive fronts. You must constantly
    balance cost and quality.
  • 3. Promoting the effective use of people,
    equipment, space, and energy Providing
    convenient location for services like restrooms,
    locker rooms, cafeterias, tool cribs and any
    other service will increase productivity.
  • 4. Provide for the convenience, safety, and
    comfort of our employees Drinking fountains,
    parking lot design and location, employee
    entrances, as well as restrooms and cafeterias
    must be convenient to all employees.
  • 5. Control project costs Budgeting and then
    living within the budget are two things that
    successful managers and engineers learn to do
    early in their careers.
  • 6. Achieve the production start date For
    seasonable products, if you miss the start date,
    you miss the whole season. Schedules must be met.
  • 7. Build flexibility into the plan Design
    buildings that will be able to support a wide
    variety of uses.
  • 8. Reduce or eliminate excessive inventory
    Inventory costs about 35 to hold. Minimize all
    forms (raw material, work in progress, finished
    goods) of inventory.
  • 9. Achieve miscellaneous goals Like using
    plug-in plug-out equipment to allow operators to
    move equipment easily for flexibility. Goals
    should be measurable and achievable.

7
The Manufacturing Facilities Design Procedure
  • Resist jumping into the layout phase before
    collecting and analyzing data
  • 1. Determine what will be produced for example a
    toolbox.
  • 2. Determine how many will be made per unit of
    time for example 1,500 per 8 hour shift.
  • 3. Determine what parts will be made or purchased
    complete some companies but all parts, and they
    are called assembly plants.
  • 4. Determine how each part will be fabricated.
    This is called process planning and is usually
    done by a manufacturing engineer.
  • 5. Determine he sequence of assembly This is
    called assembly line balancing.
  • 6. Set time standards for each operation. It is
    impossible to design a plant layout without time
    standards.
  • 7. Determine the plant rate (takt time). This is
    how fast the facility needs to produce. For
    example to make 1,500 units in 8 hours, you have
    to make a part every .32 minute (3 parts per
    minute).
  • 8. Determine the number of machines needed. For
    example if a machine has a time standard of .75
    minutes per part, .75/.32 2.34 machines. So you
    will need 3 machines.
  • 9. Balance assembly lines or work cells. Try to
    give everyone as close to the same amount of work
    as possible.
  • 10. Study material flow patterns to establish the
    best (shortest distance through the facility)
    flow possible.
  • 11. Determine activity relationships. How close
    do departments need to be to each other to
    minimize people and material movement.
  • 12. Lay out each workstation. These layouts will
    lead to department layouts, and then to the
    facility layout.
  • 13. Identify the need for personal plant and
    services, and provide the space needed.
  • 14. Identify office needs and layout as needed.
  • 15. Develop total space requirements from the
    above information.

8
The Manufacturing Facilities Design Procedure
(continued)
  • 16. Select material handling equipment.
  • 17. Allocate the area according to the space
    needed and the activity relationships established
    in 11 above.
  • 18. Develop a plot plan and the building shape.
    How will the facility fit on the property.
  • 19. Construct a master plan. This is the
    manufacturing facility design the last page of
    the project and the result of the data collected
    and the decisions made.
  • 20. Seek input and adjust. Ask your peers to see
    if they can punch holes in your design before you
    present it to management for approval.
  • 21. Seek approvals, take advice, and change as
    needed.
  • 22. Install the layout.
  • 23. Start production.
  • 24. Adjust as needed and finalize the project
    report and budget performance.

9
Types and Sources of Manufacturing Facilities
Design Projects
  • 1. New facility There are fewer restrictions
    because you do not have to be concerned with old
    facilities.
  • 2. New product Some common equipment may be
    shared with an old product. A corner of the plant
    is set aside for a new product.
  • 3. Design changes Layout may be affected by
    these changes.
  • 4. Cost reduction May find a better layout that
    will produce more products with less worker
    effort.
  • 5. Retrofit Constraints include existing walls,
    floor pits, low ceilings, and any other permanent
    fixtures that may pose an obstacle to an
    efficient material flow.
  • If designers study the flow, they can improve it
    by changing the facilities layout.

10
Computers and Simulation in Manufacturing
Facilities Design
  • Simulation can be used to predict the behavior of
    a manufacturing or service system by actually
    tracking the movements and interaction of the
    system components and aiding in optimizing such
    systems.
  • There are a number of user friendly advanced
    simulation packages available for simulating the
    working of a factory, inventory, warehousing, or
    logistics.
  • The simulation software generates detailed
    statistics describing the behavior of the system
    under study.

11
ISO 9000 and Facilities Planning
  • A large number of corporations demand their
    vendors be registered under ISO 9000 or other
    quality standards.
  • Management must continually monitor operations
    for improvement opportunities.
  • All procedures and processes must tie back to
    achieving customer satisfaction.
  • Systems should be developed to identify,
    document, evaluate, and segregate nonconforming
    occurrences.

12
Summary
  • Facilities design includes plant location,
    building design, plant layout, and material
    handling systems.
  • Manufacturing facilities design is the
    organization of the companys physical assets to
    promote the efficient use resources such as
    people, material, equipment, and energy.
  • Material handling is simply defined as moving
    material. Material handling accounts for about
    50 of all industrial injuries and from 40 to 80
    of all operating costs.
  • Facilities planners ask the six questions ( why,
    who, what, where, when, and how) about everything
    that can happen to a part flowing through a
    manufacturing facility (operation,
    transportation, inspection, storage, and delay)
    to eliminate steps, combine steps, change
    sequence of steps or simplify.
  • Muda (waste) is defined as any expense that does
    not help produce value. There are 8 kinds of
    muda overproduction, waiting, transportation,
    processing, inventory, motion, rework, and poor
    people utilization.
  • Kaizen is the Japanese word for continuous
    improvement. Every person in the company is
    encouraged to search for new ideas and
    opportunities to further improve the organization
    and its processes including reducing waste.
  • Value stream mapping (VSM) is the process of
    assessment of each component or the step of
    production to determine the extent to which it
    contributes to operational efficiency or product
    quality. VSM can reduce or eliminate excessive
    material handling, eliminate wasted space, create
    a better control of all types of inventory and
    streamline various production steps.
  • A mission statement communicates the primary
    goals and the culture of the organization to the
    facilities planner.
  • Resist jumping into the layout phase before
    collecting and analyzing data (25 steps).
  • If designers study the flow, they can improve it
    by changing the facilities layout.
  • Simulation can be used to predict the behavior of
    a manufacturing or service system by actually
    tracking the movements and interaction of the
    system components and aiding in optimizing such
    systems.
  • A large number of corporations demand their
    vendors be registered under ISO 9000 or other
    quality standards.

13
Home Work
  1. What does facilities design include?
  2. What is muda? What are the 8 kinds of muda?
Write a Comment
User Comments (0)
About PowerShow.com