Product and Process Analysis

Product and Process
Analysis
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Data required for developing good layouts
• Product Analysis
Types of products and specifications
Detail of components
Production volume
• Process Analysis
Material flow (patern, diagram, data)
Types of layout
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Input Data and Activities
• What data are critical to the facility plan?
• Categorizes the information as:
P – Product (what?)
Q – Quantity (how much?)
R – Routing (where?)
S – Support (with what?)
T – Timing (when?)
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Input Data and Activities
• Tompkins, White, et. al., categorize it as:
Product Design – what is to be produced?
Process Design – how is it to be produced?
Schedule Design – when and how much?
Product
Facility
Process
Schedule
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PRODUCT ANALYSIS
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“What kind of product should be made?”
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Product Analysis
Specification

a.Dimension, Weight, Material &
Drawing
b.Quality of product
c.Specific requirement
Volume

Production quantity & variation
Part’s
Breakdown

a.Flow process.
b.Assembly process.
c.Processing time.
d.Machine, jig, tool and other.
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Product Design
• Based on
–
–
–
–
–
Function
Aesthetics
Costs
Materials
Manufacturing Methods
Driven by market
demand
• Key point
– The product design MUST be finalized before
designing the facility. Otherwise a flexible facility is
needed.
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Tools Used in Product Design
• Product/Part Drawings
 2-D, 3-D visualization
• Exploded Assembly Diagrams
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Part drawing
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Tools Used in Process Design
A partial list (dependent on product and service):
• Process Flowcharts and Process Maps
• Make vs. Buy
• Parts Lists
• Bill of Materials
• Route Sheets
• Assembly Charts
• Operations Process Charts
• Precedence Diagrams
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Process Flowcharts
UPS
Active
Bins
Receiving
Picking
Reserve
Storage
Packing
Monogramming
Embroidering
Quality
Assurance
Back to
Vendor
Hemming
Gift
Boxing
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Shipping
Parcel
Post
Next-Day
UPS
Process Maps
Customer
Place order
Waiter
Is order
complete?
Salad Chef
Dinner Chef
N
Y
Give soup or salad order to chef
Prepare soup or
salad order
Prepare dinner
order
Give dinner order to chef
Drink
Get drinks for customer
Eat salad or
soup
Deliver salad or soup order to customer
Eat dinner
Deliver dinner to customer
Receives check
Deliver check to customer
Gives payment to
waiter
Receive payment for meal
Cash or
Credit?
Credit
Cash
Collect change,
leave tip
Bring change to customer
Run credit card through
Fill in tip
amount
Return credit slip to customer
Collect tip
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Give order
to waiter
Give order
to waiter
Make vs. Buy?
BUY
No
Can item be
purchased?
Yes
Can we
make the
item?
No
No
MAKE
BUY
Yes
Is it cheaper
for us to
make?
No
BUY
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Yes
Is the capital
available?
Yes
MAKE
Parts List
• A listing of component parts.
PARTS LIST
Company: TW Inc.
Product: Air Flow Regulator
Part No.
1050
2200
3250
3251
3252
3253
3254
3255
4150
4250
Name
Pipe plug
Body
Seat Ring
O-Ring
Plunger
Spring
Plunger Housing
O-Ring
Plunger Retainer
Lock Nut
Prepared By: JSU
Date: 6/30/2003
Drwg. No.
4006
1003
1005
1007
1009
1011
4007
Qty/unit
1
1
1
1
1
1
1
1
1
1
Material
Steel
Aluminum
Stainless Steel
Rubber
Brass
Steel
Aluminum
Rubber
Aluminum
Aluminum
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Size
0.5" x 1.00"
2.75" x 2.5" x 1.5"
2.97" x 0.87"
0.75" diam.
0.812" x 0.715"
1.4" x 0.225"
1.6" x 0.225"
0.925" diam.
0.42" x 1.2"
0.21" x 1.00"
Make/Buy
Buy
Make
Make
Buy
Make
Buy
Make
Buy
Make
Buy
Bill of Materials
• Many different types of “structured parts lists”
BILL OF MATERIALS
Company: TW Inc.
Product: Air Flow Regulator
Level
0
1
1
2
2
3
3
4
4
4
4
4
4
4
Part No.
0021
1050
6023
4250
6022
2200
6021
3250
3251
3252
3253
3254
3255
4150
Prepared By:
Date:
Name
Air Flow Regulator
Pipe plug
Main assembly
Lock Nut
Body Assembly
Body
Plunger Assembly
Seat ring
O-Ring
Plunger
Spring
Plunger Housing
O-ring
Plunger retainer
Drwg. No.
0999
4006
4007
1003
1005
1007
1009
1011
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Qty/unit
1
1
1
1
1
1
1
1
1
1
1
1
1
1
JSU
6/30/2003
Make/Buy
Make
Buy
Make
Buy
Make
Make
Make
Make
Buy
Make
Buy
Make
Buy
Make
Bill of Materials
12
Computer Device
11
Keyboard Assembly (Purchased)
10
Color Video Display Device
8
Video Panel (Purchased)
7
Circuit Board
9
Main CPU Unit
6
Power Supply Kit (Purchased)
5
PC Board Assembly
3
4
Main PC Board (Purchased)
Disk Drive Unit
2
Floppy Drive
1
Hard Drive
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Route Sheet
Company: ARC Inc.
Part:
Plunger Housing
Prepared by:
JSU
Produce:
Part No.
3254
Part No.
6/6/03
Air Flow Regulator
Oper.
No.
Operation
Description
0104
Shape, drill,
cut off
0204
Machine
Type
Auto sc.
Machine
Tooling
Setup
(hr.)
Oper.
Time
(hr.)
Mtls.
Parts
Alum
1”x12’
.5 in dia coller, cir.
Form tool, .45”
diam center drill
5
0.0057
Machine Slot Chucker
and thread
0.045” slot saw,
turret slot
2.25
0.0067
0304
Drill 8 holes
Auto dr.
unit
0.078” diam twist
drill
1.25
0.0038
0404
Debur and
Blow out
Drill press
Deburring tool with 0.5
pilot
SA 1
Enclose
Dennison
None
subassembly hydraulic
press
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0.25
0.0031
0.0100
Routing sheet
--PART
--PART NUMBER-NUMBER-- ---------DESCRIPTION------------DESCRIPTION--------------DRAWING
DRAWING REVISION
REVISION
H6709
H6709
HANDLE,DENSPLY
HANDLE,DENSPLY PROBE
PROBE
GG
MASTER
MASTER ROUTING
ROUTING LIST
LIST
ALT
ALT CODE
CODE
BUYER/PLANNER
BUYER/PLANNER
DATE
DATE
6/25/92
6/25/92
BB
239
239
--------STAND
--------STANDARD-------ARD-------TIME
TIME
MOVE
MOVE
OPER
OPER
WORK
WORK OPER
OPER SETUP
SETUP
CREW
CREW
MACH
MACH --TOOLING
--TOOLING REF-REF-BASIS
BASIS
TIME
TIME
-----EFFECT
-----EFFECTIVE---IVE---&& ALT
ALT CENTER
CENTER CODE
CODE CODE
CODE FACTOR
FACTOR GROUP
GROUP
NUMBER
NUMBER
CDE/-QTYCDE/-QTY-DAYS-DAYSFROM
FROM
TO
TO
10
10
01226
01226
1.0
1.0 01226
01226 T9330
T9330
1000
1000
.000
.000
0/00/00
0/00/00 99/99/99
99/99/99
PARTIAL
PARTIAL AHEAD
AHEAD QTY
QTY
------------------ROUTING
-ROUTING DESCRIPTIONS---------DESCRIPTIONS---------MAKE
MAKE @@ AUTO
AUTO 804843P
804843P
CC 804843P
804843P BB
AA A02247
A02247 AA
15
15
02053
02053
1.0
1.0 02053
02053 T9712
T9712
1000
1000
.000
.000
0/00/00
0/00/00 99/99/99
99/99/99
PARTIAL
PARTIAL AHEAD
AHEAD QTY
QTY
------------------ROUTING
-ROUTING DESCRIPTIONS---------DESCRIPTIONS---------DRILL
DRILL && TAP
TAP 804843P1
804843P1
BB 804843P1
804843P1 AA
20
20
02053
02053
1.0
1.0 02053
02053 T9713
T9713
1000
1000
.000
.000
0/00/00
0/00/00 99/99/99
99/99/99
PARTIAL
PARTIAL AHEAD
AHEAD QTY
QTY
------------------ROUTING
-ROUTING DESCRIPTIONS---------DESCRIPTIONS---------KNURL
KNURL OD
OD
30
30
03029
03029
1.0
1.0
1000
1000
.000
.000
0/00/00
0/00/00 99/99/99
99/99/99
PARTIAL
PARTIAL AHEAD
AHEAD QTY
QTY
------------------ROUTING
-ROUTING DESCRIPTIONS---------DESCRIPTIONS---------SCOTCHBRI
SCOTCHBRITE/BELT
TE/BELT
40
40
03105
03105
1.0
1.0 03105
03105
1000
1000
.000
.000
0/00/00
0/00/00 99/99/99
99/99/99
PARTIAL
PARTIAL AHEAD
AHEAD QTY
QTY
------------------ROUTING
-ROUTING DESCRIPTIONS---------DESCRIPTIONS---------PASSIVATE
PASSIVATE
50
50
03005
03005
1.0
1.0
1000
1000
.000
.000
0/00/00
0/00/00 99/99/99
99/99/99
PARTIAL
PARTIAL AHEAD
AHEAD QTY
QTY
------------------ROUTING
-ROUTING DESCRIPTIONS---------DESCRIPTIONS---------BUFF
BUFF
60
60
03007
03007
1.0
1.0 03007
03007
1000
1000
.000
.000
0/00/00
0/00/00 99/99/99
99/99/99
PARTIAL
PARTIAL AHEAD
AHEAD QTY
QTY
------------------ROUTING
-ROUTING DESCRIPTIONS---------DESCRIPTIONS---------GLASSBEAD
GLASSBEAD KNURL/
KNURL/ SHIP
SHIP
--SETUP--SETUP-
-LABOR-LABOR-
-MACHINE--MACHINE--
HOURS
HOURS
HOURS
HOURS
HOURS
HOURS
I/O
I/O
12.000
12.000
336.880
336.880
336.880
336.880
44
1.500
1.500
41.670
41.670
83.330
83.330
44
1.500
1.500
8.330
8.330
16.670
16.670
44
.000
.000
33.330
33.330
33.330
33.330
44
.000
.000
3.000
3.000
3.000
3.000
44
.000
.000
54.170
54.170
54.170
54.170
44
.000
.000
50.000
50.000
50.000
50.000
44
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Assembly Chart
2200
3254
Analog model of the assembly process.
3253
•
Circles denote components
3252
•
Links denote
SA-1
3251
A-1
operations/subassemblies
3250
•
Squares represent inspections
3255
operation
•
A-2
Begin with the original product and
4150
to trace the product disassembly
4250
back to its basic components.
1050
A-3
I-1
Pack
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A-4
Found by superimposing
the route sheets and the
assembly chart, a chart
results that gives an
overview of the flow within
the facility.
Operations Process Chart
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Operator-Machine Charts
• Tool for showing activity of
both operator and machine
along a time line
• Also called “multiple activity
chart”
Example:
1 minute to load
1 minute to unload
6 minute run cycle
0.5 minute to inspect and pack
0.5 minute to travel to another
machine
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ONE MACHINE
Time
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
7.5
8
Cycle Time
Oper Idle
Mach. Idle
Prod. Rate
Operator
M1
U1
UNLOAD
U1
UNLOAD
L1
LOAD
L1
LOAD
I&P
RUN
RUN
RUN
RUN
RUN
RUN
IDLE
RUN
RUN
RUN
RUN
RUN
RUN
8
5.5
0
0.125
min
min
min
pc/min
Operator Machine Charts
TWO MACHINES
Time
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
7.5
8
Cycle Time
Oper. Idle
Mach Idle
Prod Rate
THREE MACHINES
Operator
M1
M2
U1
UNLOAD
RUN
U1
UNLOAD
RUN
L1
LOAD
RUN
L1
LOAD
RUN
I&P
RUN
RUN
T-2
RUN
RUN
U2
RUN
UNLOAD
U2
RUN
UNLOAD
L2
RUN
LOAD
L2
RUN
LOAD
I&P
RUN
RUN
T-1
RUN
RUN
RUN
RUN
RUN
RUN
IDLE
RUN
RUN
RUN
RUN
8
2
0
0.25
min
min
min
pc/min
Time
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
5.5
6
6.5
7
7.5
8
8.5
9
Cycle Time
Oper. Idle
Mach Idle
Prod Rate
Operator
M1
M2
M2
U1
UNLOAD
RUN
RUN
U1
UNLOAD
RUN
RUN
L1
LOAD
RUN
RUN
L1
LOAD
RUN
RUN
I&P 1
RUN
IDLE
RUN
T-2
RUN
IDLE
RUN
U2
RUN
UNLOAD
RUN
U2
RUN
UNLOAD
RUN
L2
RUN
LOAD
RUN
L2
RUN
LOAD
RUN
I&P 2
RUN
RUN
IDLE
T-3
RUN
RUN
IDLE
U3
RUN
RUN
UNLOAD
U3
RUN
RUN
UNLOAD
L3
RUN
RUN
LOAD
L3
RUN
RUN
LOAD
I&P 3
IDLE
RUN
RUN
T-3
IDLE
RUN
RUN
9
0
1
0.333333
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min
min
min
pc/min
PROCESS ANALYSIS
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Manufacturing Process: Simple Description
$
$
Suppliers
$
Manufacturing
Manufacturing
CACAT
Material
CACAT
RECYCLE
RECYCLE
WIP Stotage WIP Stotage
WIP Stotage
Inventory
Quality Assurance
Manufacturing
Inventory
Distribution
CACAT
CACAT
RECYCLE
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Data requirement for layout decisions
• Frequency of flow of material / some other
measure of interaction between
departments
• Shape and size of departments
• Floor space available
• Location restrictions for departments, if any
• Adjacency requirements between pairs of
departments, if any
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Flow pattern at 800-acre Nissan plant in
Smyrna, TN
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Possible flow patterns
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Dendrite flow pattern
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Spine flow pattern
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Five types of layout
•
•
•
•
•
Product layout
Process layout
Fixed-position layout
Group-technology layout
Hybrid layout
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Types of Departments/Layouts
Volume
High
Product
Department
Product
Layout
Medium
Fixed Location
Layout
Fixed Materials
Location
Department
Product
Family
Department
Group Technology
Layout
Process
Layout
Process
Department
Low
Low
Medium
Source: John S. Usher class notes
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High
Variety
Product layout
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Product Layouts
Product A Department
D
D
M
G
P
D
A
L
L
M
M
D
G
P
A
Product C Department
L
L
L
G
G
P
Source: John S. Usher class notes
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A
Shipping Department
Receiving Department
Product B Department
Process layout
DM
TM
TM
VMM
DM
TM
DM
TM
VMM
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BM
BM
The Process Layout
Lathe Department
L
L
L
L
L
L
L
L
L
L
Milling
Department
Drilling Department
M
M
D
D
D
D
M
M
D
D
D
D
G
G
G
P
G
G
G
P
Grinding
Department
Receiving and
Shipping
Source: John S. Usher class notes
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Painting Department
A
A
Assembly
A
Flow of Materials in Process Layouts
Lathe Department
L
L
L
L
L
L
L
L
L
L
Milling
Department
Drilling Department
M
M
D
D
D
D
M
M
D
D
D
D
G
G
G
P
G
G
G
P
Grinding
Department
Receiving and
Shipping
Source: Russell & Taylor, 2007
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Painting Department
A
A
Assembly
A
Group technology layout
TM
BM
VMM
VMM
DM
TM
TM
DM
TM
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DM
BM
Product Family (Cellular) Layout
G
G
L
D
Rotational
Parts
Cell
M
D
G
G
L
D
L
M
G
D
L
M
D
L
G
L
M
L
D
P
P
L
L
D
Rectangular
Parts
Cell
A
Receiving and
Shipping
Source: John S. Usher class notes
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A
Special
Department
A Manufacturing Cell
Paths of three
workers moving
within cell
Material
movement
Key:
S
L
HM
VM
G
= Saw
= Lathe
= Horizontal milling machine
= Vertical milling machine
= Grinder
Direction of part movement within cell
HM
VM
Worker 3
VM
L
Worker 2
G
L
Final
inspection
S
Worker 1
In
Source: John S. Usher class notes
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Finished
part
Out
Project (Fixed-Position) Layout
G
G
D
D
D
L
G
L
L
A
L
M
A
P
Receiving and
Shipping
Source: John S. Usher class notes
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Storage
Storage
G
Hybrid layout
TM
TM
TM
VMM
BM
DM
TM
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Hybrid Layouts
• Combination of the layouts discussed.
• A combination of group layout in manufacturing cells,
product layout in assembly area, and process layout in the
general machining and finishing section is used.
TM
DM
TM
TM
BM
TM
TM
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General Characteristics
Product
Process
Product
Family
Project
Throughput Time
Low
High
Low
Medium
Work in process
Low
High
Low
Medium
Choice
High
Med-High
Mixed
Product Flexibility
Low
High
Med-High
High
Demand Flexibility
Medium
High
Medium
Medium
Mach Utilization
High
Med-Low
Medium-High
Medium
Worker Utilization
High
High
High
Medium
Can be
low
High
High
Medium
Low
High
Low
High
Characteristic
Skill Level
Reliability
Unit production
cost
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Exercise – What Type of Layout?
• Ford Louisville Assembly Plant
___________
• Suburban Hospital
___________
• Louisville International Airport
___________
• KFC Restaurant
___________
• Boeing Aircraft
___________
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Automated Manufacturing Cell
Source: John S. Usher class notes
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Flexible Manufacturing Systems
 Automated machining operations, tool changers
 Automated material handling, computer control
 Designed around size of parts processed & average
processing time for parts
 Can process wide variety of items quickly
 Very few large systems exist
• Progressive layout – all parts same route
• Closed loop – larger variety, alternative routes
• Ladder layout – two machines work on same part
• Open field layout – most complex
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Flow process chart
FLOW PROCESS CHART
Subject Charted TB03100 Face Panel
Drawing No.
Chart No. 112XAG
Part No.
Chart of Method Present
Chart Begins Receiving
Charted By N.L.
Chart Ends Steel Dept.
Dist. Time
(ft)
.02
220
20
50
Chart
Symbol
1
Date Feb. 5/90
Oper
ID
A1
Dept
ID
S&R
H2
M/C
ID
# of
pieces
100
How
moved
Truck
Process Description
MF1
100
Forklift
To crane bay area
100
100
Stored temporarily
Conveyor To hydra shear
.02
1
.02
2
2
H2
WIP1
MF1
.01
1
M1
MF1
HS1
100
.02
3
H3
MF2
13G
142
101
95
.01
2
M2
MF2
160
.03
4
H3
MF2
3
5
M2
H1
MF2
MF3
136
240
.03
.01
155
.05
4
M2
MF3
260
.01
6
3
H1
WIP2
S&R
150
.01
7
H3
WIP3
Total
 Operations
4
Inspections
Transportations
—
8
 Storages
3
of 1
Received material 0.022 wcs (51" x 102")
Cut to length (front panel)
Forklift
To machine #13G (100 ton press) or Komatsu
(machine 142) or to HYMAC 101 (7" & over neck)
Necking operation (punch hole)
95
Forklift
To machine # 136
95
95
Forklift
Punch holes
To machine #155 or machine #104 or machine #111
95
95
Braking operation
94
94
AGV
To marshalling area
Temporary storage
94
AGV
To steel dept.
Summary
Event
Sheet 1
Time
Distance
—
—
(min.) 1100 ft.
Delays
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Simbol-Simbol ASME
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Flow diagram
MESIN BUBUT
2
MESIN FRAIS
2
1
3
1
Peluncur
Bahan
1
PENERIMAAN
DIAGRAM ALIR (FLOW DIAGRAM)
MEJA
MEJA
PENYIMPANAN
ALAT
3
6
4
3
Peluncur
Bahan
5
MESIN BOR
MESIN BOR
2
7
ASSEMBLING
6
12
18
Peluncur
Bahan
7
13
6
20
PAINTING
12
Peluncur
Bahan
11
8
14
9
9
5
Peluncur
Bahan
17
16
15
Peluncur
Bahan
Peluncur
Bahan
4
10
13
8
MEJA
PERAKITAN
8
PEMANGGANG
18
GUDANG
FINISHING
7
Peluncur
Bahan
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PENGIRIMAN
Peluncur
Bahan
PENGEMASAN
5
3
11
6
Qualitative flow data
• Relationship chart
–
–
–
–
–
–
A
E
I
O
U
X
absolutely necessary
especially important
important
ordinary
unimportant
undesirable
• Percentages of A, E, I, O, U and X ratings
–
–
–
–
–
–
A
E
I
O
U
X
2-5%
3-10%
5-15%
10-25%
25-60%
depends
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Qualitative flow data
• Color coding relationships
–A
–E
–I
–O
–U
–X
Red
Orange or Yellow
Green
Blue
Uncolored
Brown
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Sample relationship chart
1. Form
A/1
2. Trim
Code
I/2
E/2
3. Treat
O/2
U
X/3
4. Assembly
U
U
E/2
U
5. Pack and Ship
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Reason
1
Bulky material
2
Ease of supervision
3
Safety
Quantitative flow data
• From-to frequency of
trips matrix
Dept
1
Dept
2
Dept
3
Dept
4
Dept 1
-
12
3
3
Dept 2
21
-
Dept 3
4
5
-
Dept 4
Dept 5
1
2
Dept 6
4
9
2
Dept
5
Det 6
8
8
8
-
4
4
15
-
19
7
19
-
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Quantitative flow data
• Frequency of trips
between departments
matrix
Dept
1
Dept
2
Dept
3
Dept
4
Dept
5
Dept
6
Dept 1
-
33
7
3
1
4
Dept 2
33
-
5
2
9
Dept 3
7
5
-
8
10
8
Dept 4
3
8
-
19
11
Dept 5
1
2
10
19
-
38
Dept 6
4
9
8
11
38
-
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Distance Measures
•
•
•
•
•
•
•
Euclidean
Squared Euclidean
Rectilinear
Tchebychev
Aisle distance
Adjacency
Shortest Path
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Euclidean, Squared Euclidean, Rectilinear
and Tchebychev
Facility j
(xj,yj)
Facility i
|yi-yj|
(xi,yi)
|xi-xj|
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Aisle Distance, Adjacency and Shortest
Path
d
Facility j
Facility i
Facility k
a
b
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HW for Gravity Method
•
Two high-speed copiers are to be located in the fifth floor of an office complex
that houses four departments of the Social Security Administration.
Coordinates of the centroid of each department as well as the average number
of trips made per day between each department and the copiers’ yet-to-bedetermined location are known and given in Table below. Assume that travel
originates and ends at the centroid of each department. Determine the optimal
location-the x and y coordinates-for the copiers.
Dept. No.
x Coordinate
y Coordinate
Average No. of Daily
Trips to Copiers
1
10
2
6
2
10
10
10
3
8
6
8
4
12
5
4
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