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Manufacturing Facilities Design and Analysis: Management and Applications of Computer Simulation and Modeling

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Unit 5 Manufacturing Facilities Design and Analysis: Management and Applications of Computer Simulation and Modeling – PowerPoint PPT presentation

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Title: Manufacturing Facilities Design and Analysis: Management and Applications of Computer Simulation and Modeling


1
Unit 5
  • Manufacturing Facilities Design and Analysis
    Management and Applications of Computer
    Simulation and Modeling

2
This Unit Focuses On
  • The plot plan
  • Management
  • 3. Applications of computer simulation and
    modeling to facility parts flow, processing,
    analysis, and management
  • 4. Advantages of computer simulation and
    modeling to facility parts flow, processing,
    analysis, and management

3
Meyers Stephens Chapter 14 Facilities Design
The Layout
  • The resulting layout is the visual presentation
    of the data collected and analyzed by the
    facilities planner.
  • It must communicate the complex results of months
    of data collection and analysis.
  • It is only as good as the data backing it up.

4
Plot Plan
  • A plot plan is an engineering diagram which shows
    the equipment layout, the positions of roads,
    buildings and other constructions inside an
    industrial facility to a defined scale.
  • In all cases the plot plan is a 'top down'
    orientation.

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8
Plot Plan Vs Group Project
  • Total amount of space anticipated for the
    proposed plant (the sum of all calculated spaces
    for machines, offices, storage, restrooms,
    shipping receiving, isles, tool room, cribs,
    cabinets, benches, assemblers, conference rooms,
    lunch rooms, stock room etc.)
  • Show all your data and calculations in a work
    sheet.

9
Plot Plan Vs Group Project
  • Your group should design an ideal layout of the
    equipment, workstations, transportation, MHS,
    storage, etc. necessary for complete production
    of your entire products.
  • The layout must be drawn to scale, dimensioned,
    in 2- or 3-D, and enclosed in a dimensioned
    facility.
  • Show the basic framework of the facilities and
    the process flow of only the parts assigned to
    you with different line types or line colors
    indicating each student.

10
The Plot Plan
  • Shows how the buildings, parking lots and
    driveways fit on the
  • property
  • Has 8 suggested steps to develop
  • Start with a layout of the property showing the
    lot lines
  • Place in the layout the main roads that border
    the property or where the access road will enter
    the property
  • Show sources of water, power, gas, and phones
  • Place the building where the front faces the road
    and the long side faces the road
  • Show receiving and shipping
  • Connect receiving and shipping to the main road
  • Show where employee and public entrances will be
    located
  • Provide parking for visitors and employees

11
Item Length X Width Sq. Ft X No of Stations Total Square Ft
Milling Machine XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Injection Molding Machine XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Paint Systems XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Puch Press XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Assembly XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Parking XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Stores XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Milling Machine XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Sawing machines XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Offices XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Lockers XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Assembly XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Parking XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Stores XXXXXXXXXX XXXXXXXXXX XXXXXXXXXX
Total Square Feet XXXXXXXXXX
12
Plant Layout Methods
  • Template and tape technique
  • Three-dimensional models technique
  • Computer-aided design (CAD) technique

13
Master Plan
  • Is the finished product of the facilities design
    project
  • Shows where every machine, workstation,
    department, desk, and all other items are located
  • A scale of 1/4 1 ft or 1/8 1ft is
    recommended

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17
Obi, Chapter 12
  • Managing and Improving Manufacturing Systems

18
Manufacturing Management (or Control) Defined
  • Checking current performance of a system against
    pre-determined or set standards
  • Seeing that tasks are being carried out according
    to set plans.
  • Measurement and correction of performance to
    ensure that objectives and the plans devised to
    attain them are accomplished.
  • What are being managed or controlled are
    manufacturing systems
  • Machines, tooling, equipment, facilities,
    production methods, processes, procedures,
    quality assurance, production control, materials,
    material moving and handling systems, people, and
    the end products

19
Steps in Control
  • Establishment of performance standards.
  • Measuring the actual or realized performance.
  • Comparing the measured performance against the
    established standards.
  • Taking corrective action as needed.

20
Some Areas of Management
21
Personnel Management
  • Seeking competent employees
  • Hiring competent employees
  • Training competent employees
  • Motivating employees
  • Evaluating employees
  • Rewarding employees

22
Personnel Management
23
Quality Control
  • Process control
  • Product characteristics
  • Design specifications
  • Customer needs and characteristics
  • Equipment utilization

24
Facility Management
  • Building
  • Energy
  • Safety
  • Scheduling
  • Maintenance
  • Equipment
  • Maintenance
  • Scheduling
  • Arrangement
  • Materials
  • Scheduling
  • Storage
  • Quality
  • Quantity

25
Inventory Management
  • Materials
  • Machines
  • Tools
  • Tooling (jigs, molds, dies, punches etc)
  • Hardware (nuts, screws, washers etc)
  • Stationeries
  • Janitorial supplies
  • Software
  • Others

26
Supply Chain Management
  • Is based on the idea that every product that
    reaches the customer is a result of the efforts
    of many organizations at various levels.
  • These multi-level organizations are generally
    called the supply chain.
  • The management of the entire chain of activities
    is known as supply chain management.

27
Supply Chain Management
28
Applications of Computer Simulation and Modeling
  • Simulation is defined as an experimental
    technique, usually performed on a computer, to
    analyze the behavior of any real-world operating
    system
  • Simulation can be used to predict the behavior of
    a complex manufacturing or service system by
    actually tracking the movements and the
    interaction of the system components
  • The simulation software generates reports and
    detailed statistics describing the behavior of
    the system under study
  • The physical layouts, equipment selection,
    operating procedures, resource allocation and
    utilization, inventory policies, and other system
    characteristics can be evaluated based on these
    reports

29
Advantages of Simulation
  • Flexible and straightforward
  • Can be used for large and complex models that may
    not lend themselves to mathematical models
  • Allows for study of the interactive effects of
    many components in a dynamic and stochastic
    environment
  • Can be used to study alternative ideas

30
Disadvantages of Simulation
  • Can be very expensive and time consuming to
    develop
  • Results may not be exactly what is needed
    (garbage-in-garbage-out)

31
How Simulation Works
  • The purpose of simulation is to help the decision
    maker solve a particular problem
  • There are 10 basic steps in simulation

32
Ten basic steps in simulation
  • Problem definition (clearly define problem and
    state the goals)
  • System definition (define the boundaries and
    restrictions of system in terms of resource
    availability)
  • Conceptualize model (develop a graphical model to
    define system components, variables etc.)
  • Preliminary design (what data are needed? in what
    form? etc.)
  • Input data preparation (gabage-in-gabage-out)

33
Ten basic steps in simulation (continued)
  • 6. Model translation (develop working knowledge
    of simulation package)
  • 7. Verification and validation
  • 8. Experimentation
  • 9. Analysis and interpretation
  • 10. Implementation and documentation

34
Uses of Simulation
  • For evaluation
  • For comparison
  • For prediction
  • For sensitivity analysis
  • For optimization
  • For bottleneck analysis

35
Some Simulation Packages
  • SIMPROCESS
  • ProModel
  • FactoryFLOW
  • FACTOR/AIM
  • ARENA

36
SIMPROCESS Steps
37
SIMPROCESS Hammer Example
38
SIMPROCESS Hammer Example (Process Flow)
39
SIMPROCESS Hammer Layout Example
40
SIMPROCESS Simulation Example
41
SIMPROCESS Tool Pallet
42
SIMPROCESS Hammer Results
43
Simulation Practice Exercises
To Be Assigned
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