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IE304 LectureNotes 1
IE304 LectureNotes 1
IE304 LectureNotes 1
Manufacturing Processes
INPUTS
Material
Manufacturing Processes:
a) consist of physical
Labor
elements interacting
Information
with each other
Capital
b) can be monitored via
performance measures
Energy
Physical Elements
Machinery
Tools
Computerized Equipment
People
Material Handling Equipment
Products
Performance Measures
Production rate
% On-Time Delivery
Defects per Million
Unit cost
Inputs:
Raw vegetables
Metal Sheets
Water
Energy
Labor
Building
Equipment
Chemicals
Coloring material
Processes:
Cleaning
Making Cans
Cutting
Cooking
Packing
Labelling
Outputs:
Canned vegetables
Inputs:
Doctors
Nurses
Other personnel
Building(s)
Equipment
Labs
Medical supplies
Processes:
Examination
Surgery
Monitoring
Medication
Therapy
Outputs:
Treated patients
Products vs Services
Products:
Tangible
Can be stocked
No interaction between customer
and process
Services:
Intangible
Cannot be stocked
Direct interaction between
customer and process
Service industries have been on the rise and constitute most of the economy
in the Western world.
Manufacturing Systems
1. Product Design: blueprints, Computer-Aided Design
2. Process Planning:
Sequence of operations to convert raw material into
finished goods
Machine selection: Right equipment and tools to be able to process
parts according to design specifications
3. Production/Manufacturing Operations:
Fabrication: Drilling a hole, plastic injection molding, bending a flange
Assembly: Combination of separate parts into a more valuable
combined unit
4. Material Flow/Facilities Layout:
Material Handling: Techniques for transporting parts, tools, scrap in
the facility
Facility Layout: Placing production facilities, power supply,
compressed air within the facility
5. Production Planning/Control:
Use market demand, consider production capacity and current inventory
levels, determine planned production levels by product family.
6
Product Layout
Process Layout
Group Technology
Fixed Position (not to be covered)
The types of products in terms of their volume, variety dictate the layout. In
other words, these 4 layouts are not alternatives to one another.
Characteristics:
1. Makes few products in large volume
2. Uses specialized high-volume equipment
3. Workstations and machines for production are specific for the
product, and cannot be easily adjusted to other products.
4. Short throughput time, low WIP (work-in-process) inventories
10
11
12
13
Assembly Lines
Assembly operation: joins two or more components to create a
new entity, which is called an assembly, or subassembly.
Assembly line: A production line consisting of a sequence of
workstations where assembly tasks are performed by human
workers or machines as the product moves along the line.
Organized to produce a single product or a limited range of
products
Each product consists of multiple components joined together by
various assembly work elements
15
Assembly Lines
on each unit
Assembly Lines
Factors favoring the use of assembly lines:
High or medium demand for product
Identical or similar products
Total work content can be divided into work elements
Interchangeable parts
Each component is manufactured to sufficiently close tolerances
Line pacing
Workers are required to complete their assigned tasks on each unit within a
certain cycle time
A specified production rate is maintained
17
Assembly Lines
Advantages
Assembly lines reduced production cost and increased
production volume
Keeps direct labor or automated machines busy doing
productive work
Minimal setup times since the tasks are repeated
Assembly lines do not require large queues, thus
reduced WIP and lower inventory holding cost
reduced space requirements
shorter throughput time
18
Assembly Lines
Most consumer products are assembled on assembly
lines
Automobiles
Cooking ranges
Dishwashers
Dryers
Furniture
Lamps
Luggage
Microwave ovens
Personal computers
Power tools
Refrigerators
Telephones
Toasters
Trucks
Video DVD players
Washing machines
19
21
Assembly workstations
Work Transport Systems
Manual transport systems
Mechanized transport systems
22
Assembly Workstations
Workstation: A designated location along the work flow
path at which one or more work elements are
performed by one or more workers
Typical operations performed at assembly stations
Adhesive application
Electrical connections
Snap fitting
Sealant application
Component insertion
Soldering
Arc welding
Press fitting
Stitching/stapling
Spot welding
Riveting
Threaded fasteners
23
Types:
Work units moved in batches
Work units moved one at a time
Problems:
o Starving of stations worker is available for the next unit, but
the unit has not yet arrived
24
Synchronous transport
Work units are moved simultaneously with stop-and-go
(intermittent) motion to next stations
Asynchronous transport
Work units are moved independently between workstations
Queues of work units can form in front of each station
25
Continuous Transport
Synchronous Transport
Asynchronous Transport
C=?
29
Cycle Time
Bottleneck station establishes the cycle time for the entire line
30
Problem:
Assign tasks to the minimum number of stations
such that the workload assigned to each station does
not exceed the cycle time and the idle time is
minimized.
31
=1
Precedence constraints: IP
Zone constraints: ZS and ZD
32
Precedence Constraints
Restrictions on the order in which work elements can be
performed
IP = {(u,v): task u is an immediate predecessor of task v }
Precedence
diagram
IP = ?
33
Zone Constraints
Limitations on the grouping of tasks and/or their
allocation to workstations
ZS: Positive zoning constraints
Tasks should be grouped at same station
Example: spray painting elements
ZS = {(u,v) | u and v must be assigned to the same station}
Problem Formulation
35
(LB - I)
min
Problem Formulation
m
c
i 1 j 1
i, j i, j
Sum of task times of tasks assigned to each station cannot exceed cycle time
m
t x
i 1
i i, j
C , j 1,..., n
i,j
j 1
1,
i 1,...,m
x
j 1
u, j
xv , j 1, (u,v) ZS
36
min max ti xi , j
j
s.t.
i 1
n
1, i 1,...,m
i,j
j 1
x
j 1
u , j v, j
1, (u,v) ZS
(LB - II)
min
s.t.
C
m
t x
i 1
n
i i, j
x
j 1
i,j
C j 1,..., n
1, i 1,...,m
h
x
j 1
u , j v, j
1, (u,v) ZS
40
Number of workstations
4
1
=4
41
ti
Preceded
by
0.7
0.6
3, 4
11
0.5
9, 10
0.4
10
0.38
5, 8
0.32
0.3
0.27
6, 7, 8
0.2
12
0.12
11
0.11
0.1
1, 2
42
Task
(i)
ti
Preceded
by
0.7
Station
Task
ti
0.4
0.6
3, 4
0.3
11
0.5
9, 10
0.2
0.4
0.1
10
0.38
5, 8
0.7
0.32
0.11
0.3
0.6
0.27
6, 7, 8
10
0.38
0.2
0.32
12
0.12
11
0.27
0.11
11
0.5
0.1
1, 2
12
0.12
2
3
4
Station Time
1.0
0.81
0.98
0.59
0.62
43
44
Column
ti
Preceded
by
0.4
0.2
II
0.7
II,III
0.3
II
0.1
1, 2
III
0.6
3, 4
III
0.32
III
0.11
10
IV
0.38
5, 8
IV
0.27
6, 7, 8
11
0.5
9, 10
12
VI
0.12
11 46
2
3
4
5
Task
Column
ti
0.4
0.2
II
0.3
II
0.1
II
0.7
III
0.11
III
0.6
III
0.32
10
IV
0.38
IV
0.27
11
0.5
12
VI
0.12
Station
Time
1.0
0.81
0.92
0.65
0.62
47
()
48
RPWi
ti
Preceded
by
3.30
0.2
3.00
0.7
2.67
0.4
1.97
ti
0.2
0.7
0.4
0.1
1, 2
0.1
1.87
0.6
3, 4
0.3
1.30
0.3
0.11
1.21
0.32
0.6
1.00
0.11
0.32
10
1.00
0.38
5, 8
10
0.38
0.89
0.27
6, 7, 8
0.27
11
0.62
0.5
9, 10
11
0.5
12
0.12
12
0.12
0.12
11
3
4
5
Station
Time
0.9
0.91
0.92
0.65
0.62
49
n C ti
i 1
nC
Example: C = 100 min, 3 tasks with task times 75, 50, and 70
min
Assign each task to one station (n = 3)
Balance delay is D = 0.35
50
We can produce a unit within 100 mins with one less workstation
Cycle time is 200 min for each station, but the balance delay is
D = 0.025
In general, with K parallel stations ( or number of workers that can
be grouped) with KxC as the cycle time for each station, excessive
idle time can be shortened
51
E sj
iS j
Var s j
iS j
2
i
52
If all stations are created under this rule, the probability that ALL n
stations complete their tasks within C is 0.99
In the case of random process times, we can assign utility workers
to help assembly workers in case of difficulty or provide for a rework
area where they can complete the unfinished tasks.
53
Unpaced lines
In a paced line, each item spends nC time units in the system.
In an unpaced line, the slowest station is the bottleneck station, which
blocks the preceeding stations and starves the succeeding stations.
Then, flow time of a product in an unpaced line is
nb snb
j nb 1
1
snb
54
Mixed Lines
Several different product types can be assembled simultaneously and
continuously (not in batches).
Stations are sufficiently flexible that they can perform their respective tasks
on different models.
Mixed lines typically used to accomplish final assembly of automobiles,
small and large trucks, major and small appliances.
The amount of work required to assemble the units can vary from model to
model, creating an uneven flow of work along the line.
Problems in designing and operating a mixed assembly line:
Line balancing - same basic problem as in single product assembly line
except differences in work elements among models must be considered
Model launching - determining the sequence in which different models will be
launched onto the line
55
56
Preceded by
Preceded by
5, 6
Construct the precedence diagram for each model and for both of the models
combined into one diagram.
Suppose that the line is up and operating 94% of the time. Use the Kilbridge
and Wester method to solve the line balancing problem.
57
for model A
for model B
AB
AB
AB
AB
AB
AB
RA tiA
RB tiB
TTi
12
18
30
16
24
40
18
26
24
30
54
12
12
16
12
28
24
24
20
24
44
II
III
IV
AB
AB
AB
AB
AB
AB
Task
Column
TTi
Proceeded by
30
II
54
II
40
II
26
III
28
III
24
III
12
IV
44
5, 6, 7
Arrange tasks
according to the
columns
59
Task
TTi
30
26
56
54
54
40
12
28
24
52
44
44
Station Time
52
60
Fixed-rate launching
Time interval between two consecutive launches is constant
The time interval depends on the product mix and production
rates of models
Models must be launched in a specific sequence
61
=1
where
=
=
for j = 1,,P
+
=1
62
Preceded
by
Preceded
by
Station
Task
TTi
30
26
56
54
54
40
12
28
24
52
5, 6
44
44
27
4
5
Station
Time
52
25
=5
27
=
= 5.4
5
=
25
= 5
5
1
(4 27 + 6 25)
10
=
= 5.16
5
63
+
=1
+
=1
0.0576
0.0256
0.0064
0.1024
.1024
0.0064
0.0256
0.0576
0.16
0.0576
0.0256
0.0064
0.1024
0.1024
0.0064
0.0256
0.0576
10
0.16
The sequence is
B-A-B-A-B-B-A-B-A-B
64