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

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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

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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.

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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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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.

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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.

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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

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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
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Plant Layout Methods

• Template and tape technique
• Three-dimensional models technique
• Computer-aided design (CAD) technique

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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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Obi, Chapter 12

• Managing and Improving Manufacturing Systems

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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

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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.

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Some Areas of Management
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Personnel Management

• Seeking competent employees
• Hiring competent employees
• Training competent employees
• Motivating employees
• Evaluating employees
• Rewarding employees

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Personnel Management
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Quality Control

• Process control
• Product characteristics
• Design specifications
• Customer needs and characteristics
• Equipment utilization

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Facility Management

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

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Inventory Management

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

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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.

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Supply Chain Management
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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

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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

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Disadvantages of Simulation

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

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How Simulation Works

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

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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)

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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

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Uses of Simulation

• For evaluation
• For comparison
• For prediction
• For sensitivity analysis
• For optimization
• For bottleneck analysis

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Some Simulation Packages

• SIMPROCESS
• ProModel
• FactoryFLOW
• FACTOR/AIM
• ARENA

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SIMPROCESS Steps
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SIMPROCESS Hammer Example
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SIMPROCESS Hammer Example (Process Flow)
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SIMPROCESS Hammer Layout Example
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SIMPROCESS Simulation Example
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SIMPROCESS Tool Pallet
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SIMPROCESS Hammer Results
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Simulation Practice Exercises
To Be Assigned