Design of Manufacturing Systems – Job

Shop
Outline

• General features
• Strengths and weaknesses
• Examples
• System design

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Job shop – general features
In a job shop machines are grouped on the basis of
technological processes involved (similar machines in the
same department).
Each product(*) has its own routing in the system.

A A B B C
A B C

D D E
E

(*)
Product and part are terms used as synonymous during this course 3
Job shop – general features
In a job shop materials are moved according to the required
product routings (i.e. from one department to another).
The logistics (material handling through the factory) is
characterized by high flexibility.

A A B B C
A B C

D D E
E

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Job shop – general features
In a job shop the labor is divided in departments according
to task specialization: workers are skilled on the basis of
technological processes involved.

A A B B C
A B C

D D E
E

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Job shop – Strengths

 High flexibility
Short to medium-term flexibility
 Mix
 Volume
 Product (customization)
Medium to long-term flexibility
 Product (innovation)
 Expansion

Thanks to basic flexibility in the production system:

 Machine flexibility
 Material handling flexibility
 Routing flexibility

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Job shop – Strengths

Subsequently:

 Low impact of breakdowns

 Low obsolescence of the system

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Job shop – Weaknesses

 Limitations in efficiency (machine efficiency)

 Qualitative characteristics of the product can
vary for different pieces
2a 2b
 Production management is difficult
 High WIP 1
 Lead times are long (because of queues) and
characterized by high variability
 Difficulties in estimating delivery lead times
 Low utilization rate of machines

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Job shop – Weaknesses

 It is difficult to calculate production capacity that

depends on
 Mix of jobs that have to be manufactured
 Technological characteristics of jobs
 Complexity of pieces to be manufactured
 Possibilities to use alternative routings
 Number of machines and their state
 Lot sizes
 Ability to schedule jobs

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Example 1
Processes
Layout and
machinery Torni

Frese

taglio

Saldatura

Rettifica

Saldatura

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Example 2

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Example 3

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Some examples

 https://www.youtube.com/watch?v=gJWMCUM
dO4Q

 https://www.youtube.com/watch?v=V-9eMmfT
hD8

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Some examples

 Seethis long video for your own:

https://www.youtube.com/watch?v=hWz8_KbB
2t0

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Typical questions related to system design

 How many machines do we need to meet demand?

 How many operators do we need to meet demand?
 Where are the bottlenecks?
 What happens if the production mix changes?
 What happens if a machine break downs?
 What is the effect of reducing setup times or lot sizes?
 What is the effect of adding another machine to the
system?
 …..

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Rough design of a job-shop – STEP 1

 Production mix definition

 Identify all the product types
 Estimate yearly demand for each product type
 Define the lot sizes for each product type

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Rough design of a job-shop – STEP 2

 Routing definition
 Define the main routing for each product type
 If possible, define alternative routings

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Rough design of a job-shop – STEP 3

 Machine identification
 On the basis of routings, it is possible to identify all
the machine types that are necessary to
manufacture the production mix

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Rough design of a job-shop – STEP 4

 Foreach product type, calculate the total time

of the operations that have to be done on the
same type of machine

Tij

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Rough design of a job-shop – STEP 5

 Calculatethe yearly workload NHi for each type

of machine i

 Tij  Q j STTij  1 1 1
NH i   j 1  
N
  NL j   
 3600  1  SR  60  A HC TR
 ij  i i i

where
i = index of the machine-type
j = index of the product-type
 N= number of different product-types

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 Rough design of a job-shop – STEP 5

 Tij = unit working time [seconds/piece]

 Qj = quantity of product-type j that has to be produced [pieces/year]
 SRij = scrap rate (0  SRij  1)
 STTij = setup time [minutes/setup]
 NLj = number of lots of product-type j [lots/year]
 Ai = availability (0  Ai  1)
 HCi = human coefficient (0 < HCi  1)
 TRi = trial rate (0 < TRi  1)

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Rough design of a job-shop – STEP 6

 Calculate the number of hours available for each

machine-type i

AHi(s) = WHi(s)  SE

where
 WHi(s) =yearly working time available (depending on the
number of shifts per day)
 SE = scheduling efficiency (0  SE  1)

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Rough design of a job-shop – STEP 7

 Calculate the number of machines of type i

necessary to manufacture the production mix,
given the yearly demand

NH i
NM i ( s ) 
AH i ( s )

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Rough design of a job-shop – STEP 8

 Thenumber that has been obtained must be

rounded up or down depending on
 Machine-type cost
 Possibility to outsource the production of some
product-types
 Possibility to use alternative routings for some
product-types

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Rough design of a job-shop – STEP 8

 Evaluate the number of shifts/day, computing the

yearly costs adopting 1, 2 or 3 shifts/day

WFi(s) + OCi(s) + NMi(s)CAimi + FCi(s)fi

 WFi(s) = yearly cost of direct and indirect labor
 OCi(s) = yearly operating costs (e.g. energy costs)
 NMi(s) = number of type-i machines
 CAi = cost of a type-i machine
 FCi(s) = installation costs of facilities
 mi, fi = coefficients used to split costs on the machine
lifetime or facility lifetime
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Rough design of a job-shop – EXAMPLE

Job X

# Ma c hine -typ e Wo rking Se tup Sc ra p

tim e tim e c o e ff.
1 La th e s 2’ 60’ 0.01
2 Millin g m a c h in e s 2’ 40’ 0.05
3 Drillin g m a c h in e s 4’ 30’ 0.05

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Rough design of a job-shop – EXAMPLE

Job Y

# Ma c hine -typ e Wo rking Se tup Sc ra p

tim e tim e c o e ff.
1 La th e s 2’ 20’ 0.01
2 Millin g m a c h in e s 2’ 50’ 0.05
3 Drillin g m a c h in e s 3’ 20’ 0.05

1 operator for each machine

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Rough design of a job-shop – EXAMPLE

DATA X Y
Ye a rly d e m a n d [u n its/ ye a r] 10000 50000
Lo t size [u n it/ lo t] 100 200
Hu m a n C o e ffic ie n t 0.9 0.9

Ye a rly w o rkin g d a ys 220

Ho u rly c o st (first sh ift) 15 €/ m a n h o u r
Ho u rly c o st (se c o n d sh ift) 18 €/ m a n h o u r
Ho u rly c o st (th ird sh ift) 20 €/ m a n h o u r

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Rough design of a job-shop – EXAMPLE

Type of machine Capacity Availability Cost

(jobs that is possible % (x1.000 €)
to work at the same
time)
X Y
Turning 1 1 100 50
Milling 1 1 98 150
Drilling 1 1 95 100

Amortization period: 5 years

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