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Chapter 2 Heragu
Chapter 2 Heragu
Equipment Analysis
Data required for developing good
layouts
• Product Analysis
• Process Analysis
Input Data and Activities
• What data are critical to the facility plan?
• Muther categorizes the information as:
P – Product (what?)
Q – Quantity (how much?)
R – Routing (where?)
S – Support (with what?)
T – Timing (when?)
Product Analysis
• Bill of Materials
• Assembly Charts
• Engineering Drawing
• Operation Process Chart
• Route Sheet
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
Product Design
• Based on
• Function
• Aesthetics Driven by market
• Costs demand
• Materials
• Manufacturing Methods
• Key point
• The product design MUST be finalized before designing the
facility. Otherwise a flexible facility is needed.
Tools Used in Product Design
• Product/Part Drawings
• 2-D, 3-D visualization
Active Parcel
Receiving Picking Packing Shipping
Bins Post
Embroid-
Quality
ering
Assurance
Back to
Vendor
Hemming
Gift
Boxing
Process Maps
Customer Waiter Salad Chef Dinner Chef
N
Place order Is order
complete?
Y
Give soup or salad order to chef Prepare soup or
salad order
Gives payment
to waiter Receive payment for meal
Cash or Credit
Credit?
Cash
Collect change,
leave tip Bring change to customer
Fill in tip
amount Return credit slip to customer
Collect tip
Make vs. Buy? BUY
No
No No No Yes
BILL OF MATERIALS
Company: TW Inc. Prepared By: JSU
Product: Air Flow Regulator Date: 6/30/2003
Assembly Chart
3254
• Links denote
3250
operations/subassemblies
3255
• Squares represent inspections A-2
operation 4150
components.
Assembly Charts
1
3 5 9
7
10
8 12
11
Operation process chart for 3.5 volt
halogen otoscope
TC W S B P LHS T FB LH OL LN LR PS L
Dr
Th
Mi Dr Mi
Th LA
Tu
Pl LHA A1
LPA
A2
BA A3
HO
Found by superimposing
the route sheets and the
assembly chart, a chart
results that gives an
overview of the flow within
the facility.
Units/yr
Percent
K 1120 92% 8000 60%
A 1000 95% 6000
40%
E 650 98% 4000
D 450 99% 2000
20%
B 100 99% 0 0%
H 100 100% C F G J K A E D B H I
I 81 100% Products
Volume Variety Chart
Product Units/year Percent
P 800 13%
F 766 26%
900 120%
C 600 36%
800
J 542 45% 100%
G 513 53% 700
Units/Yr
K 475 69%
Percent
500
60%
A 423 76% 400
Q 418 83% 300 40%
E 322 89% 200
D 234 93% 100
20%
B 100 94%
0 0%
H 100 96% P F C J G O K A Q E D B H N I L M
N 100 98% Products
I 81 99%
L 52 100%
M 16 100%
Production Requirements –
Yield Loss
Pi – Production input to operation i
Pi i Oi
si – Fraction of Pi lost (scrap)
Oi Pi Pi si Oi
Pi
Oi Pi (1 si ) (1 si )
Production Requirements –
Series Systems
P1 1 2 ... n On
On
P1
(1 s1 )(1 s2 ) (1 sn )
Example
• 5 processes in series
• Need 2000 units out
Process Loss Out In
5 3% 2000 2062
4 2% 2062 2104
3 1% 2104 2125
2 2% 2125 2169
1 1% 2169 2190
2000
P1 2190
(1 .01)(1 .02)(1 .01)(1 .02)(1 .03)
Production Requirements – Non Series
Part A Part B
m
• Subject to x
j 1
ij NOi i =1,2,...,o
o
t x
i 1
ij ij j NM j j =1,2,...,m
y j 1
ij NPi i =1,2,...,p
s
i 1
ij yij j NMH j j =1,2,...,m
LP equipment selection model (cont)
m n
C NM H NMH
i 1
i i
i 1
i i B
6 12 8 10 5
[cij]= 4 20 4 [hij]= 12 6
12 10 5 18 9
6 3
LP Model for example
• MIN 90000 NMH1 + 130000 NMH2 + 230000 NM1 + 250000 NM2
• + 310000 NM3 + 6 X11 + 12 X12 + 8 X13 + 4 X21 + 5 X22
• + 4 X23 + 12 X31 + 5 X32 + 5 X33 + 10 Y11 + 5 Y12 + 12 Y21
• + 6 Y22 + 18 Y31 + 9 Y32 + 6 Y41 + 3 Y42
• SUBJECT TO
• C1) X11 + X12 + X13 >= 200
• C2) X21 + X22 + X23 >= 200
• C3) X31 + X32 + X33 >= 150
• C4) - 300 NM1 + 1.67 X11 + 2.5 X21 + 0.83 X31 <= 0
• C5) - 300 NM2 + 0.833 X12 + 2 X22 + 2 X32 <= 0
• C6) - 300 NM3 + 1.25 X13 + 2.5 X23 + 2 X33 <= 0
• C7) Y11 + Y12 >= 2000
• C8) Y21 + Y22 >= 1500
• C9) Y31 + Y32 >= 1800
• C10) Y41 + Y42 >= 1000
• C11) - 300 NMH1 + 0.1 Y11 + 0.0833 Y21 + 0.056 Y31 + 0.167 Y41 <= 0
• C12) - 300 NMH2 + 0.2 Y12 + 0.167 Y22 + 0.11 Y32 + 0.33 Y42 <= 0
• C13) 90000 NMH1 + 130000 NMH2 + 230000 NM1 + 250000 NM2
• + 310000 NM3 <= 1000000
• END
• GIN 5
LP Model Solution
• VARIABLE VALUE REDUCED COST
• NMH1 2.000000 90000.000000
• NMH2 .000000 105454.546875
• NM1 2.000000 228562.875000
• NM2 1.000000 248353.593750
• NM3 .000000 308353.593750
• X11 200.000000 .000000
• X12 .000000 2.571524
• X13 .000000 .860030
• X21 59.880245 .000000
• X22 140.119751 .000000
• X23 .000000 1.744012
• X31 140.119751 .000000
• X32 9.880246 .000000
• X33 .000000 .000000
• Y11 2000.000000 .000000
• Y12 .000000 11.363637
• Y21 1500.000000 .000000
• Y22 .000000 7.663636
• Y31 1800.000000 .000000
• Y32 .000000 .000000
• Y41 1000.000000 .000000
• Y42 .000000 24.000002
Parameters for LP equipment
selection model
• rik number of times operation Oi is to be
performed on part type Pk
• cijk cost of performing operation Oi using
production equipment type Mj on part type Pk
• tijk time required to perform operation Oi using
production equipment type Mj on part type Pk
• xijk number of units of operation Oi performed
using production equipment type Mj on part
type Pk
• Cj purchase cost of production equipment type
Mj prorated over the planning period
LP equipment selection model
o m p m
• Min c
i 1 j 1 k 1
x C j NM j
ijk ijk
j 1
m
• Subject to x j 1
ijk rik NPk i =1,2,...,o; k =1,2,...,p
o p
t
i 1 k 1
x j NM j
ijk ijk j =1,2,...,m
WIP 5 14
Flow Time 0.5 1
Personnel requirements analysis
• n number of types of n
Ti Oi
operations
N
i 1 H
• Oi aggregate number of
operation type i required on
all the pseudo (or real)
products manufactured per
day
• Ti standard time required
for an average operation Oi
• H total production time
available per day
• η assumed production
efficiency of the plant
Queuing Model
The American Automobile Drivers’ Association (AADA) is the only
office serving customers in New York’s greater capital district area.
Ahead of the busy summer season, the office manager wants to hire
additional staff members to help provide these services to members
effectively - summer travel planning, membership renewal,
disbursing traveler’s checks, airline, hotel, and cruise booking, and
other travel related services.
It is anticipated that each customer typically requires 10 minutes of
service time and customers arrive at the rate of one customer every
three minutes.
The arrival process is Poisson and the service times are
exponentially distributed.
Determine how many staff members are required if the average
wages and benefits per staff member are $20 per hour and the
“cost” to AADA for every hour that a customer waits to be served is
$40.
M/M/m Model Solution
Number of staff members (m) 4 5 6
Arrival rate 20 20 20
Service Rate 6 6 6
Machine Utilization 0.83 0.67 0.56
Time in queue 0.1447 0.0261 0.0075
Hourly Cost $195.74 $120.85 $126.01
Production space requirement sheet
Departme Work Work Lengt Width Area Auxiliar Operato Materia Sub- Allowanc Total Number Total
nt Name Center Center h (feet) (feet2 ) y Area r Space l Space Total e (feet2) space per of Space
Name Code (feet) (feet 2) (feet2 ) (feet 2) (feet2 ) machine Machine Machine
(feet2 ) s Type
(feet2 )