Manufacturing to Facilities

Design and Materials Handling

(Some notes from book by
Meyers & Stephes)
 Chapter 1 Highlights
• Manufacturing Facilities Design
– Organization of physical faciliteis to maximize
efficiencies
• Material handling
– Moving stuff
• Fork Trucks
• Conveyors
• Employees
- Accounts for apx 50% of injuires,
- Accounts for apx 40%-80% of costs
 Buzzwords
• Lean Manufacturing- Less of everything is better
• Muda - Waste
• Kaizen - Continous Improvement
• VSM - Value Stream Mapping
• Mission Statement – Primary Goals
• ROI – Return On Investment
• Value Added – Work that Transforms materials.
• Takt Time – Operating Time/Production Requirements
• Root Cause – 5 whys
• Pokayoke – Fool Proofing
• JIT – Just In Time
ISO 9000 is a family of standards for quality
manange systems:
• a set of procedures that cover all key processes in the
business;
• monitoring processes to ensure they are effective;
• keeping adequate records;
• checking output for defects, with appropriate and
corrective action where necessary;
• regularly reviewing 9000 – International Standards
for Quality management individual processes and the
quality system itself for effectiveness; and
• facilitating continual improvement
 Subgoals of Mission Statement
1. Minimize unit and Production Cost
2. Optimize quality
3. Promote Effective use of:
– People
– Equipment
– Space
– Energy
4. Provide for:
– Employee Convenience
– Employee Safety
– Employee Comfort
• Control Project Costs
• Achieve Production Start Date
• Flexibility in the plan
• Reduce or eliminate useless inventory
• Achieve Miscellaneous Goals
 5 S’s Principals
• Sifting
– Keeping only what is needed
• Sorting
– Puts things in their proper place
• Sweeping
– Cleaning
• Spick and Span
– Safety
• Strict
– Following Procedures, everyone on the same page
 Types of MF Design Projects

1. New Facility
2. New Product (returns)
3. Design Changes
4. Cost Reduction
5. Retrofit