Escolar Documentos
Profissional Documentos
Cultura Documentos
O PM
CAPACITY PLANNING & FACILITIES LAYOUTS
By: HAKEEMURREHMAN PCBAUCP
CAPACITY PLANNING
Capacity Planning is the longterm strategic decision that establishes a firms overall level of resources. Strategy Formulation With respect to Capacity Planning: Capacity strategy for long-term demand which focus on demand patterns and takes into account growth rate and variability Facilities that focus on cost of building and operating Technological changes relate to rate and direction of technology changes Behavior of competitors Availability of capital and other inputs Key Decisions of Capacity Planning Some of the common key decisions are Amount of capacity needed Timing of changes Need to maintain balance Extent of flexibility of facilities
CAPACITY PLANNING STRATEGY of capacity Three basic strategies for the timing
expansion in relation to a steady growth in demand. Capacity Lead Strategy Average Capacity Strategy Capacity Lag Strategy
Moderate Strategy Capacity is expanded to coincide with average expected demand. Conservative Strategy Capacity is increased after an increase in demand has been documented.
CAPACITY DECISIONS
ECONOMIES OF SCALE
fixed costs can be spread over a larger number of units production or operating costs do not increase linearly with output levels quantity discounts are available for material purchases operating efficiency increases as workers gain experience
DISECONOMIES OF SCALE
unit to produce.
FACILITY LAYOUT
Arrangement of areas within a facility to:
Minimize material-handling costs Utilize space efficiently Utilize labor efficiently Eliminate bottlenecks Facilitate communication and interaction Reduce manufacturing cycle time Reduce customer service time Eliminate wasted or redundant movement Increase capacity
Facilitate entry, exit, and placement of material, products, and people Incorporate safety and security measures Promote product and service quality Encourage proper maintenance activities Provide a visual control of activities Provide flexibility to adapt to changing conditions
TYPES OF LAYOUTS
Basic Layouts
Process Layout Product Layout FixedPosition Layout Cellular Layouts Flexible Manufacturing Systems MixedModel Assembly Lines
Hybrid Layouts
BASIC LAYOUTS
Process layouts
Product layouts
arrange activities in line according to sequence of operations for a particular product or service
Fixed-position layouts
Womens dresses
Childrens department
Womens sportswear
Mens department
L L L L L
L L L L L
M M G G
M M G G
Grinding Department Receiving and Shipping
D D G G
D D P P
D D
D D
Painting Department
A
Assembly
A PRODUCT LAYOUT
In
Out
FIXED-POSITION LAYOUTS
Typical of projects Equipment, workers, materials, other resources brought to the site Highly skilled labor Often low fixed Cost Typically high variable costs
Relationship Diagramming
based on location preference between areas use when quantitative data is not available
BLOCK DIAGRAMMING
STEPS create load summary Unit load chart quantity in which calculate composite (two material is normally way) movements moved develop trial layouts Nonadjacent load minimizing number of distance farther nonadjacent loads than the next block
Department 1 1 2 3 4 5 60
2 100 100
3 50 200 50
4 50 40
50 60
3 4
4
Grid 1 2
5 3
40
RELATIONSHIP DIAGRAMMING
Schematic diagram that uses weighted lines to denote location preference Muthers grid
format for displaying manager preferences for department locations
A E I O U X
O U A U O
A O U O
I X O
E U
Objective
Balance the assembly line tries to equalize the amount of work at each workstation physical restrictions on the order in which operations are performed maximum amount of time a product is allowed to spend at each workstation
Line balancing
Precedence requirements
Cycle time
production time available Cd = desired units of output (8 hours x 60 minutes / hour) Cd = (120 units) 480 Cd = = 4 minutes 120
Cycle time = max time spent at any station Flow time = time to complete all stations
EFFICIENCY OF LINE
Efficiency Minimum number of workstations
i i
E = nC a
where
t
i=1
N=
t
i=1
Cd
ti j n Ca Cd
= completion time for element i = number of work elements = actual number of workstations = actual cycle time = desired cycle time
5. 6.
Draw and label a precedence diagram Calculate desired cycle time required for the line Calculate theoretical minimum number of workstations Group elements into workstations, recognizing cycle time and precedence constraints Calculate efficiency of the line Determine if the theoretical minimum number of workstations or an acceptable efficiency level has been reached. If not, go back to step 4.
WORK ELEMENT A B C D
Press out sheet of fruit Cut into strips Outline fun shapes Roll up and package
B
0.1
A C
0.4
D 0.3
B
0.1
0.2
A C
0.4
D 0.3
A, B
0.3 minute
C
0.4 minute
D
0.3 minute
Cd = 0.4 N = 2.5
CELLULAR LAYOUTS group dissimilar machines into work centers (called cells) that process families of parts with similar shapes or processing requirements FLEXIBLE MANUFACTURING SYSTEM automated machining and material handling systems which can produce an enormous variety of items MIXED-MODEL ASSEMBLY LINE processes more than one product model in one line
HYBRIDS LAYOUTS
CELLULAR LAYOUTS
1. 2.
3.
4.
Identify families of parts with similar flow paths Group machines into cells based on part families Arrange cells so material movement is minimized Locate large shared machines at point of use
PARTS FAMILIES
A family of similar parts
A family of related grocery items
1 x
2 x
Machines 4 5 6 7 x x x x x x x x
8 9 10 11 12 x x x x x x x x x
x x x x x
x x
x x
x x
12 11 Cell 3 7 5
Raw materials A
11
A D F C G B H
x x x
x x
x x x
x x x x x x x x x x x x x x x x x x x
FMS consists of numerous programmable machine tools connected by an automated material handling system and controlled by a common computer network FMS combines flexibility with efficiency FMS layouts differ based on
variety of parts that the system can process size of parts processed average processing time required for part completion
FULL-BLOWN FMS
Produce multiple models in any order on one assembly line Issues in mixed model lines
9 min Efficiency =
12 min
3 min
C,D
Efficiency =
12 min
QUESTION S