12/5/2015 IENG 471 Facilities Planning 1 IENG 471 - Lecture 03 Product & Process Design.
4/17/2015 IENG 471 Facilities Planning 1 IENG 471 - Lecture 05 Group Technology – Production Flow...
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Transcript of 4/17/2015 IENG 471 Facilities Planning 1 IENG 471 - Lecture 05 Group Technology – Production Flow...
04/18/23 IENG 471 Facilities Planning 1
IENG 471 - Lecture 05
Group Technology –
Production Flow Analysis
04/18/23 IENG 471 Facilities Planning 3
Assignments
Current Assignment: HW 4Download spreadsheet from the Group Technology II Link on the
Materials page – follow the steps for Kings’ Algorithm HW: (HW 4) See Assignment Link
Individual AssignmentCan work together in groups, but each person turns in their own
assignmentPRINT out the initial and final matrix for each problemHighlight the family cells on the final matrixInterpret the final matrix of family cells – list which items
compose each family, AND discuss how that affects the operation of the facility
Next Assignment: Exam I
04/18/23 IENG 471 Facilities Planning 4
Volume, Variety & AutomationP
rod
uc
tio
n Q
ua
nti
ty
Part VarietyLow Medium High
High
Medium
Low
1 10 100 1,000
100,000
10,000
1,000
100
1
Mfg Cell
NC Machine
Flexible Mfg Sys
Transfer Line
Batch Flow Line
Increasing Productivity
Increasing Flexibility
Rembold, et. al.
04/18/23 IENG 471 Facilities Planning 5
Layout Impact on Facility’s Machines
Job Shop LayoutGroup by individual machinesAdd all equipment fractions, then round up*
Mass Production LayoutGroup by individual productsRound up* all equipment fractions, then add
Cellular LayoutGroup by similar part-process familiesAdd family equipment fractions, then round up*,
then add
* Multiply number of each machine type by footprint size after rounding to find the actual space required
04/18/23 IENG 471 Facilities Planning 6
Layout Patterns
Process Layout
Product Layout
Family / GT Cell Layout
Fixed Location Layout
Low Medium High
Product Variety
Low
Med
ium
Hig
h
Pro
duct
Vol
ume
Bulky, Difficult to Move Prod. (Planes, ships, etc.)
Bulky, Difficult to Move Equip.
(Precision fixtures)
Can Have Combinations (HYBRIDS)!
04/18/23 IENG 471 Facilities Planning 7
Examples
For the following situations, what type of General Layout would you suggest? The assembly of bodies for GM midsize SUVs
Fabrication & Assembly of custom made sheet metal parts
Fabrication of computer cases for a line of desktop PCs, plus custom made sheet metal parts
Assembly of three distinct families of electronic cards for inkjet printers
Production of high quality, custom office furniture
04/18/23 IENG 471 Facilities Planning 8
Group Technology (GT)
Philosophy:Use the similarity of current products to simplify
the design and manufacturing of new products Some Applications:
Identify and reuse similar process plansIdentify and reuse similar CNC programsIdentify the equipment that may be best used in a
particular machine cellIdentify and eliminate redundant inventory
Requirement:A taxonomy of part characteristics
04/18/23 IENG 471 Facilities Planning 9
Benefits of GT
Facilitates formation of part families and machine cells
Quick retrieval of designs, drawings, & process plans
Reduces design duplication
Provides reliable workpiece statistics
Facilitates accurate estimation of machine tool requirements and logical machine loadings
Permits rationalization of tooling setups, reduces setup time, and reduces production throughput time
Allows rationalization and improvement in tool design
Aids production planning and scheduling procedures
Improves cost estimation and facilitates cost accounting procedures
Provides for better machine tool utilization and better use of tools, fixtures, & people
Facilitates NC part programming.
(Ham)
04/18/23 IENG 471 Facilities Planning 10
How to Identify Groups
Similar Design AttributesSize of partsGeometric shape of partsMaterialsTechnique: Parts Classification & Coding
Similar Manufacturing AttributesCommon processing steps (routings)Common tools and fixturesTechnique: Production Flow Analysis
Similarity groupings are called Part Families
04/18/23 IENG 471 Facilities Planning 11
PFA Introduction PFA is Production Flow Analysis
A subset of Group Technology (GT)
Goals: Reduce material transport efforts Reduce set up efforts Reduce work in process inventory
Steps: Identify OP-Codes for each Component
Routing/Process Planning information for each part Incidence Matrix Blocking (Triangularization) Algorithm Cluster Identification
04/18/23 IENG 471 Facilities Planning 12
OP-Codes
An OP-Code forms an index to an Operation Plan
An Operation Plan is a generalized sequence of steps, perhaps common to multiple parts
An OP-Code Sequence is a method of condensing the Operation Plan into a compact structure suitable for data processing
04/18/23 IENG 471 Facilities Planning 13
OP-Code Example
OP Code Operation Plan01 Saw01 Cut to size02 Lathe02 Face end
Center drillDrillReamBoreTurn straightTurn grooveChamferCut offFaceChamfer
03 Grind01 Grind04 Insp06 Inspect dimension
Inspect finish
Rotational Part
(sectional view)
04/18/23 IENG 471 Facilities Planning 14
OP-Code ExampleOP Code Operation Plan01 Saw01 Cut to size02 Lathe02 Face end
Center drillDrillReamBoreTurn straightTurn grooveChamferCut offFaceChamfer
03 Grind01 Grind04 Insp06 Inspect dimension
Inspect finish
OP Code Sequence01 Saw01
02 Lathe02
03 Grind01
04 Insp06
04/18/23 IENG 471 Facilities Planning 15
Incidence Matrix
Rows represent OP-Codes (index = i) Columns represent Components (index = j) Cell Entries are: (Mij)
1 (or mark) - if the component requires the operation 0 (or blank) - if the component does NOT require the operation
A-112 A-115
Saw01 1
Lathe01
Lathe02 1
Drill01 1
Mill02 1
Mill05
Grind05 1
04/18/23 IENG 471 Facilities Planning 16
King’s Algorithm – Step 1 Calculate the total (binary) weight of each column j:
Wj = 2i Mij
i
A1 A2 A3 A4 A5 A6 A7 A8 A9 A0 2i i
S01 1 1 1 1 1 1 2 1
L01 1 4 2
L02 1 1 1 1 1 8 3
D01 1 1 16 4
M02 1 32 5
M05 1 1 1 64 6
G05 1 128 7
G06 1 256 8
Wj
138 48 10 6 10 64 64 10 10
336
Rank 5 3 2 1 2 4 4 2 2 6
After Chang, Wysk, & Wang (1998) p.500
04/18/23 IENG 471 Facilities Planning 17
King’s Algorithm – Step 2
Sort the columns into rank order, then go to Step 3:
A4 A3 A5 A8 A9 A2 A6 A7 A1 A0
S01 1 1 1 1 1 1
L01 1
L02 1 1 1 1 1
D01 1 1
M02 1
M05 1 1 1
G05 1
G06 1
Wj 6 10 10 10 10 48 64 64
138
336
Rank 1 2 2 2 2 3 4 4 5 6
04/18/23 IENG 471 Facilities Planning 18
King’s Algorithm – Step 3
A4 A3 A5 A8 A9 A2 A6 A7 A1 A0 Wi Rank
S01 1 1 1 1 1 1 574 4
L01 1 2 1
L02 1 1 1 1 1 602 5
D01 1 1 1088 7
M02 1 64 2
M05 1 1 1 1408 8
G05 1 512 3
G06 1 1024 6
2j
2 4 8 16 32 64
128
256
512
1024
j 1 2 3 4 5 6 7 8 9 10
Calculate the total (binary) weight of each row i:
Wi = 2j Mij
j
04/18/23 IENG 471 Facilities Planning 19
King’s Algorithm – Step 4
A4 A3 A5 A8 A9 A2 A6 A7 A1 A0 Wi Rank
L01 1 2 1
M02 1 64 2
G05 1 512 3
S01 1 1 1 1 1 1 574 4
L02 1 1 1 1 1 602 5
G06 1 1024 6
D01 1 1 1088 7
M05 1 1 1 1408 8
If all rows are in rank order STOP; otherwise, sort the rows into rank order, and then go to Step 1:
04/18/23 IENG 471 Facilities Planning 20
King’s Algorithm – Step 1 (2nd time)
A4 A3 A5 A8 A9 A2 A6 A7 A1 A0 2i i
L01 1 2 1
M02 1 4 2
G05 1 8 3
S01 1 1 1 1 1 1 16 4
L02 1 1 1 1 1 32 5
G06 1 64 6
D01 1 1 128 7
M05 1 1 1 256 8
Wj 18 48 48 48 48
132
256
256 56
448
Rank 1 2 2 2 2 4 5 5 3 6
Calculate the total (binary) weight of each column j:
Wj = 2i Mij
i
04/18/23 IENG 471 Facilities Planning 21
King’s Algorithm – Step 2 (2nd time)
A4 A3 A5 A8 A9 A1 A2 A6 A7 A0
L01 1
M02 1
G05 1
S01 1 1 1 1 1 1
L02 1 1 1 1 1
G06 1
D01 1 1
M05 1 1 1
Wj 18 48 48 48 48 56
132
256
256
448
Rank 1 2 2 2 2 3 4 5 5 6
Sort the columns into rank order, then go to Step 3:
04/18/23 IENG 471 Facilities Planning 22
King’s Algorithm – Step 3 (2nd time)
A4 A3 A5 A8 A9 A1 A2 A6 A7 A0 Wi Rank
L01 1 2 1
M02 1 128 5
G05 1 64 2
S01 1 1 1 1 1 1 126 4
L02 1 1 1 1 1 124 3
G06 1 1024 6
D01 1 1 1152 7
M05 1 1 1 1792 8
2j
2 4 8 16 32 64
128
256
512
1024
j 1 2 3 4 5 6 7 8 9 10
Calculate the total (binary) weight of each row i:
Wi = 2j Mij
j
04/18/23 IENG 471 Facilities Planning 23
King’s Algorithm – Step 4 (2nd time)
A4 A3 A5 A8 A9 A1 A2 A6 A7 A0 Wi Rank
L01 1 2 1
G05 1 64 2
L02 1 1 1 1 1 124 3
S01 1 1 1 1 1 1 126 4
M02 1 128 5
G06 1 1024 6
D01 1 1 1152 7
M05 1 1 1 1792 8
If all rows are in rank order STOP; otherwise, sort the rows into rank order, and then go to Step 1:
04/18/23 IENG 471 Facilities Planning 24
King’s Algorithm – Step 1 (3rd time)
A4 A3 A5 A8 A9 A1 A2 A6 A7 A0 2i i
L01 1 2 1
G05 1 4 2
L02 1 1 1 1 1 8 3
S01 1 1 1 1 1 1 16 4
M02 1 32 5
G06 1 64 6
D01 1 1 128 7
M05 1 1 1 256 8
Wj 18 24 24 24 24 26
160
256
256
510
Rank 1 2 2 2 2 3 4 5 5 6
Calculate the total (binary) weight of each column j:
Wj = 2i Mij
i
04/18/23 IENG 471 Facilities Planning 25
King’s Algorithm – Step 2 (3rd time)
A4 A3 A5 A8 A9 A1 A2 A6 A7 A0
L01 1
G05 1
L02 1 1 1 1 1
S01 1 1 1 1 1 1
M02 1
G06 1
D01 1 1
M05 1 1 1
Wj 18 24 24 24 24 26
160
256
256
510
Rank 1 2 2 2 2 3 4 5 5 6
Sort the columns into rank order, then go to Step 3:
NO CHANGE IN SORTED ORDER!
04/18/23 IENG 471 Facilities Planning 26
King’s Algorithm – Step 3 (3rd time)
A4 A3 A5 A8 A9 A1 A2 A6 A7 A0 Wi Rank
L01 1 2 1
G05 1 64 2
L02 1 1 1 1 1 124 3
S01 1 1 1 1 1 1 126 4
M02 1 128 5
G06 1 1024 6
D01 1 1 1152 7
M05 1 1 1 1792 8
2j
2 4 8 16 32 64
128
256
512
1024
j 1 2 3 4 5 6 7 8 9 10
Calculate the total (binary) weight of each row i:
Wi = 2j Mij
j
04/18/23 IENG 471 Facilities Planning 27
King’s Algorithm – Step 4 (3rd time)
A4 A3 A5 A8 A9 A1 A2 A6 A7 A0 Wi Rank
L01 1 2 1
G05 1 64 2
L02 1 1 1 1 1 124 3
S01 1 1 1 1 1 1 126 4
M02 1 128 5
G06 1 1024 6
D01 1 1 1152 7
M05 1 1 1 1792 8
If all rows are in rank order STOP; otherwise, sort the rows into rank order, and then go to Step 1:SINCE THE ROWS WERE IN RANK ORDER, WE STOP! (yea!)
04/18/23 IENG 471 Facilities Planning 28
Partitioning
A4 A3 A5 A8 A9 A1 A2 A6 A7 A0
L01 1
G05 1
L02 1 1 1 1 1
S01 1 1 1 1 1 1
M02 1
G06 1
D01 1 1
M05 1 1 1
Ideally, the cells form mutually exclusive blocks (as below). These blocks define the Families: Family A consists of Components A1, A3, A4, A5, A8, and A9; which
can be machined in a cell performing Operations G05, L01, L02, and S01
Family B consists of Components A0, A2, A6, and A7; which can be machined in a cell performing Operations D01, G06, M02, and M05
04/18/23 IENG 471 Facilities Planning 29
Partitioning
A4 A3 A5 A8 A9 A1 A2 A6 A7 A0
L01 1
G05 1
L02 1 1 1 1 1
S01 1 1 1 1 1 1
M02 1
G06 1 1
D01 1 1
M05 1 1 1
Often, the cells do NOT form mutually exclusive blocks (as below). In this case, the capability for Operation G06 must be common to both machining cells: Family A consists of Components A1, A3, A4, A5, A8, and A9; which can be
machined in a cell performing Operations G05, G06, L01, L02, and S01 Family B consists of Components A0, A2, A6, and A7; which can be
machined in a cell performing Operations D01, G06, M02, and M05
04/18/23 IENG 471 Facilities Planning 30
Strategies for Overlapping PFA Blocks:
Provide for transporting some components between cells requiring the overlapping operation(s)
Pick the component(s) with the smallest volume(s) to transport to reduce handling costs
Locate the cells with operation overlap as near to each other as possible to reduce handling costs
Avoid scheduling concurrent production runs of the components that require overlapping operation(s)
Assumes that the equipment providing the overlapping capability can be easily moved between cells
This solution may improve capacity if the overlapping operation is a bottleneck
Put equipment capable of the overlapping operation(s) into each cell requiring it
Assumes the additional equipment capability is cost justifiableThis solution will improve capacity if the overlapping operation is a
bottleneck
04/18/23 IENG 471 Facilities Planning 31
Extended GT (PFA) Requirements:
Need for grouping similar items together, and identifying separable items
Matrix of related entities:ToolingEquipmentPartsIntegrated CircuitsModular Components
Solution Method: TriangularizationDirect Clustering AlgorithmKing’s MethodKusiak’s Triangularization MethodUllman’s Design Structure Matrix
04/18/23 IENG 471 Facilities Planning 32
Relationship (Incidence) Matrix
Rows and Columns:Parts requiring operations on different machinesTools (in a CNC magazine) needed to produce
part familiesDepartments requiring technicians (shared head
count)Departments requiring adjacent locationICs requiring modularization
An entry in the incidence matrix means that there is a strong relationship between the row and column items