Fulfill Order

8/9/2019 Fulfill Order

1/26

29/11/2011

1

FULFILL ORDERFULFILL ORDERManufacturing Process

Manufacturing System

Motion and Time Study

Facilities La out

Manufaktur ?Manufaktur ?

RI 1321 Proses Manufaktur - Minggu 1 2

Definisi ManufakturDefinisi Manufaktur

Kata-kata manufaktur berasal dari bahasa latin (manus =

hand, factus =made)

Definisi manufacturing oleh Random House

Websters College Dictionary:

The making of goods or wares by manual labor or by

R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 3

machinery, esp. on a large scale.

Definisi dari National Science Foundations Workshop:

The creation and integration of informational and physical

processes to create economic wealth through the production of

artifacts. NSF 93-69.

Contoh Produk ManufakturContoh Produk Manufaktur



2/26

29/11/2011

2

Manufaktur (Technology Perspective)Manufaktur (Technology Perspective)


Manufaktur (Economic Perspective)Manufaktur (Economic Perspective)


Klasifikasi Industri Manufaktur (1)Klasifikasi Industri Manufaktur (1)Berdasarkan North American Industry Classification System (NAICS)Berdasarkan North American Industry Classification System (NAICS)

Food manufacturing,

Beverage & tobacco productmanufacturing,

Textile mills,

Wood productionmanufacturing

Paper manufacturing

Fabricated metal productmanufacturing

Machinery manufacturing

Computer and electronicproduct manufacturing

Electrical equip, appliance &component manufacturing


Petroleum and coal productionmanufacturing

Chemical manufacturing

Plastic and rubberproduct manufacturing

Non-metallic mineralmanufacturing

Primary metalmanufacturing

Transportation equipmentmanufacturing

Furniture and related productmanufacturing

Miscellaneousmanufacturing

Klasifikasi Industri Manufaktur (2)Klasifikasi Industri Manufaktur (2)

Primary vs. secondary manufacturing Primary manufacturing adalah industri yang menghasilkan produk berupa

material yang akan diolah lebih lanjut, seperti steel mill s, textile mills,plastics.

Secondary manufacturing industri yang menghasilkan komponen atauproduk fungsional.

Discrete manufacturing vs. continuous manufacturing


Discrete manufacturing adalah produsen komponen, part atau singleproduct, seperti gir, mobil, pesawat udara, dll.

Continuous manufacturing adalah produsen produk yang sifatnyakontinu seperti karet, plastic, sheet metal working, dll.

Mechanical manufacturing, vs. electronics manufacturingand chemical manufacturing

Klasifikasi berdasarkan disiplin ilmu


3/26

29/11/2011

3

Klasifikasi Industri Manufaktur BerdasarkanKlasifikasi Industri Manufaktur Berdasarkan

Standard ISIC 2 DigitStandard ISIC 2 Digit


Proses Vs System ManufakturProses Vs System Manufaktur

R I 1 32 1 P ro se s M an uf ak tu r -M ing gu 1 1 0

Jenis Material yang dipergunakanJenis Material yang dipergunakan

Metals Ceramics

and othersPlastics Composites

F er ro us No nfer ro us Thermoplastic Thermoset Polymer Matrix

Metal Matrix

Ceramic Matrix


Stainless

Steels

Tool and

Die Steels

Cast Irons

Oxides

Nitrides

Carbides

Glasses

Graphite

Diamond

Alumi num

Copper

Magnesium

Titanium

Polypropylene

Nylon

ABS

PVC

Epoxy

Phenolic

Silicone

HalHal--hal yang akan dipelajarihal yang akan dipelajari

Mainly secondary, discrete, and mechanicalmanufacturing processes Casting, Forging, Rolling, Extrusion, Sheet

Metal Working, Machining, Non-traditional

Machining, Polymer Processing, Powder


eta urgy nter ng, rocess ng o eramcsand Composites, and Joining.

Common aspects of manufacturingprocesses Dimensioning and Tolerance, Engineering

Metrology, Design of Experiment, ProcessCapability, Statistical Process Control, etc.


4/26

29/11/2011

4

Manufacturing ProcessManufacturing Process

1. Subtractive Process

Machining: Turning, milling, boring, grinding

Non-traditional machining: EDM, chemicalmilling, waterjet, etc.

Micro-electronics processes: Primarily etchingtype processes using either masks or beam

2. Additive Process

Rapid Prototyping Very flexible to part

3. Continuous Process

Pultrusion of composites

Metal Extrusion Net shape process

Plastic Extrusion

Czochralski Crystal Growth

Continuous Casting

4. Net shape Process


s ape; usua y mte n matera c oces; sowrates; fully automated

Advanced Composites Processes Combination of additive and net shapeprocesses

Microelectronics Processes Physical andchemical vapor deposition processes andcoating methods

Joining & Assembly Broad category includeswelding, adhesives, and mechanical assembly

Solids: Metal Forming, Powders, Others

Liquids: Casting, Injection Molding, Others

Mixtures: Infiltration, Viscoelastics, Others

Characteristics

Hard tooling

Solid forming very fast cycle time

Thermal processes slower and depend uponcooling rate

Dimensional control is not as good asmachining

Injection MouldingInjection Moulding


Metal CastingMetal Casting


ForgingForging



5/26

29/11/2011

5

Sheet Metal StampingSheet Metal Stamping


Plastic ExtrusionPlastic Extrusion


Metal ExtrusionMetal Extrusion


WeldingWelding



6/26

29/11/2011

6

Blanking and PunchingBlanking and Punching


MillingMilling


Water Jet MachiningWater Jet Machining


ManufakturManufaktur Mengapa penting ?Mengapa penting ?

Proses manufaktur adalah kegiatan inti dari sebuah perusahaan.

Adanya kebutuhan terkait dengan Concurrent Enginnering

Design for X: manufacture, assembly, environment, etc.

61% alumni Teknik Industri ITS (berdasarkan hasil tracer study 2005 yangmelibatkan 86 responden lulusan dalam 4 tahun terakhir) bekerja di bidangmanufaktur


esgn ngneers, ro uct ngneers, esearc an eve opment, anuactur ngEngineer, Planning, Safety, Materials, etc.

6% Dosen/Wiraswasta/Pegawai Pemerintah, dll.

33% Sektor Jasa Konsultan. Credit Company, Bank, dll

Di Amerika Serikat Industri menyumbangkan 20% GDP

Sektor Jasa : 70% U.S. GNP (retail, transportation, banking, education,communication, insurance and government).

Pertanian, Konstruksi, dan lain-lain : 10%

Bagaimana dengan peranan industri di Indonesia ?


7/26

29/11/2011

7


Proporsi pekerjaan Alumni TI ITS

33%

6%


61%

Manufaktur Jasa Dosen / Wiraswasta

Responden : 86 orang lulusan periode 2001-2004

CIMOSA (PRODUK SEBAGAICIMOSA (PRODUK SEBAGAI

DASAR)DASAR) Sebuah industri manufaktur diawali/didorong oleh

keberadaan produk yang dihasilkan (dijual) & adanya siklus

hidup produk

Industri manufaktur umumnya menghasilkan produk dalam

jumlah besar dan sebagian part (pembentuk produk) dapat

berasal dari perusahaan lain.

Keputusan paling sederhana keputusan buat-beli

Produk

Part 1 Part 2

Part Be li Part Buat

Part HasilPerakitan

Part HasilForging

Part HasilTurning

... Part n

Keputusan buat beli make or buy

Perkenalan

Pertumbuhan

Maturity

Penurunan

Inovasi

CIMOSA (ARSITEKTUR BISNIS DALAMCIMOSA (ARSITEKTUR BISNIS DALAM

MANUFAKTUR)MANUFAKTUR) Apabila sebuah industri telah berjalan untuk menerima order,

melakukan produksi dan mengirimkan barang jadi kepada customer

maka kebutuhan pengaturan menjadi semakin bertambah dan

kompleks


8/26


9/26

29/11/2011

9

DEFINISI SISTEM PRODUKSIDEFINISI SISTEM PRODUKSI

Serangkaian peralatan, prosedur, operator/peopleuntuk menyelesaikan seluruh operasi manufakturdalam sebuah perusahaan

Kategori:

Fasilitas abrik dan eralatan dalam fasilitas danbagaimana penataan fasilitas tersebut (plant layout)

Sistem penunjang manufaktur serangkaianprosedur yang dipergunakan perusahaan untukmengelolla produksi dan menyelesaikanpermasalahan logistik dan teknis dalam pemesanan

material, aliran kerja dalam pabrik, dan memastikanbahwa produk memenuhi standar kualitas

SISTEM PRODUKSISISTEM PRODUKSI

SistemPenunjang

Manufaktur

Fasilitas

Produksi

FASILITAS SISTEM PRODUKSIFASILITAS SISTEM PRODUKSI

Fasilitas terdiri dari pabrik, mesin produksi, peralatan,material handling, peralatan inspeksi, dan juga sistemkomputer yang mengendalikan operasi manufaktur

Tata letak fasilitas cara pengaturan peralatan secara

untuk perangkat non-fisik misalnya software (virtuallayout)

Sistem produksi pengkategorian/penggolonganperalatan dan pekerja dalam pabrik

Lini produksi

Stasiun kerja tunggal dan pekerja/operator


Terdapat 3 kategori dalam partisipasi humanoperator dalam proses yang ada di sistemproduksi:

1. Sistem kerja manual seorang pekerja

melakukan satu atau lebih aktivitas ker a tan aalat bantu mekanik-elektrik, tetapimenggunakan hand tools

2. Sistem mesin dan pekerja seorang pekerjamengoperasikan peralatan yang menggunakansumber energi untuk pergerakannya

3. Sistem otomasi sebuah proses yang dilakukanmesin tanpa partisipasi langsung dari operator


10/26

29/11/2011

10

SISTEM KERJA MANUALSISTEM KERJA MANUAL

Penggunaan

hand tools

Pekerja

ProsesUnit pekerjaan

awal

Unit pekerjaan

selesai

SISTEM MESIN & PEKERJASISTEM MESIN & PEKERJA

Mesin

Pekerja

ProsesUnit pekerjaan

awal

Unit pekerjaan

selesai

SISTEM OTOMASISISTEM OTOMASI

Pekerja datang

secara periodik

Mesin

otomatis

Unit pekerjaan

awal

Unit pekerjaan

selesai

SISTEM PENUNJANG MANUFAKTURSISTEM PENUNJANG MANUFAKTUR

Melibatkan siklus aktivitas pengolahan informasidengan empat fungsi sebagai berikut:

1. Fungsi bisnis pemasaran dan penjualan,penerimaan order, akuntansi,customer billing(tagihan)

2. Design produk penelitian dan pengembangan,design engineering, pembuatan prototype

3. Perencanaan manufaktur perencanaan proses,perencanaan produksi, MRP, perencanaan kapasitas

4. Pengendalian manufaktur kendali lantai produksi,pengendalian persediaan, pengendalian kualitas


11/26

29/11/2011

11

SIKLUS PEMROSESAN INFORMASISIKLUS PEMROSESAN INFORMASI

DALAM SISTEM PENUNJANGDALAM SISTEM PENUNJANG

MANUFAKTURMANUFAKTUR

Desain

Produk

Pesanan dari

customer

Perencanaan

manufakturFungsi bisnis

Pengendalian

manufaktur

Sistem

Produks

i

OTOMASI SISTEM PRODUKSIOTOMASI SISTEM PRODUKSI

Terdapat dua kategori otomasi dalam sistem

produksi:

1. Otomasi lantai produksi dalam pabrik

. omputer sas s stem penun ang manu a tur

Apabila kedua hal tersebut diintegrasikan

maka sistem akan disebut sebagai

Computer-Integrated Manufacturing (CIM)

COMPUTER INTEGRATEDCOMPUTER INTEGRATED

MANUFACTURINGMANUFACTURING

Sistem Computer

Sistem

penunjang

manufaktur

Aplikasi

komputer

potensial

Produksi Integrated

ManufacturingFasilitas:

Peralatan

Pabrik

Potensi

aplikasi

otomasi

KOMPONEN SISTEM MANUFAKTURKOMPONEN SISTEM MANUFAKTUR

OTOMATISOTOMATIS

Contoh:

Peralatan permesinan otomatis

Transfer lines

Sistem perakitan otomatis

o o n us r yang me a u an operas prosesatau perakitan

Material handling dan sistem penyimpananotomatis untuk mengintegrasikan operasimanufaktur

Sistem inspeksi otomatis (automatic inspectionsystems ) untuk pengendalian kualitas


12/26

29/11/2011

12

SISTEM PENUNJANG MANUFAKTURSISTEM PENUNJANG MANUFAKTUR

TERKOMPUTERISASITERKOMPUTERISASI

Tujuan:

Mengurangi upaya yang bersifat manual danclerical dalam design produk, perencanaanmanufaktur, perencanaan dan pengendalian

,

Mengintegrasikan computer-aided design (CAD)dengan computer-aided manufacturing (CAM)dalam kerangka CAD/CAM

CIM mengintegrasikan fungsi CAD/CAM ke

dalam fungsi bisnis perusahaan

TENAGA KERJA MANUAL DALAMTENAGA KERJA MANUAL DALAM


Apakah ada tempat bagi pekerja manual dalam

sistem produksi modern?

Jawabnya: YA

a am ua aspe :

1. Pekerja manual dalam operasi pabrik

2. Pekerja dalam sistem penunjang manufaktur

PEKERJA MANUAL DALAM OPERASIPEKERJA MANUAL DALAM OPERASI

PABRIKPABRIK

Terdapat kecenderungan untuk menggantikanpekerja manual dengan sistem otomasi

Pertimbangan apa memanfaatkan pekerja manual?

Beberapa negara memiliki tingkat upah rendah dan

Aktivitas operasi secara teknologi terlalu sulit untukdibuat otomasi

Siklus hidup produk pendek

Produk khusus (customized) perlu fleksibilitas manusia

Mengikuti fluktuasi jumlah permintaan produk

Mengurangi resiko produk gagal/cacat

PEKERJA DALAM SISTEM PENUNJANGPEKERJA DALAM SISTEM PENUNJANG

MANUFAKTURMANUFAKTUR

Perancang produk yang menghasilkan kreativitasdalam pekerjaan design

Manufacturing engineer yang melakukan

Perancangan peralatan dan mesin produksi Perencanaan metode dan urutan produksi

Pemeliharaan peralatan

Pemrogramaan dan melakukan operasi komputer

Pekerjaan proyek teknik

Manajemen pabrik


13/26

29/11/2011

13

LINGKUP KAJIAN SISTEMLINGKUP KAJIAN SISTEM

MANUFAKTURMANUFAKTURLingkup Kajian Sistem Manufaktur seharusnya

Termasukinteraksi

dengan fungsibisnis lainnya

Sales &Marketing

AccountingSupplier

Sistem

Penunjang

Manufaktur

Sistem Penunjang

Manufaktur

Sistem Pengendalian

Kualitas

Level Enterprise

Level Factory

Groover

Fasilitas

Sistem

Produksi Sistem Manufaktur

Teknologi

Otomasi & Kendali

Teknologi

Material Handling

Proses manufaktur dan operasi perakitan

Sistem manufaktur terdiri dari seluruh komponen sistem produksiberikut dengan fungsi interaksi dengan fungsi bisnis lainnya secara

keseluruhan secara vertikal dan horizontal

Motion and Time StudyMotion and Time Study

Motion and time study can reduce and control costs, improve workingconditions and environment, and motivate people.

The basic purpose is to improve the work and to reduce waste .

1. Motion analysis techniques

2. Time study techniques

3. Uses of time standards.

Manufacturing management and engineering students are being preparedto design work stations, develop efficient and effective work methods,establish time standards, balance assembly lines, estimate labor costs,develop effective tooling, select proper equipment, and layoutmanufacturing facilities.

However, the most important thing is to learn how to train productionworkers in these skills and techniques so they can become motion andtime conscious.

Motion study offers a great potential for savings in any area ofhuman effort. We can reduce the cost by combining elements ofone task with elements of another.

Motion study uses the principles of motion economy to developwork stations that are friendly to the human body and efficient intheir operation.

Motion stud must consider the o erators safet

Time study can reduce cost significantly well. Time standards aregoals to strive for. In organizations that operate without timestandards, 60% performance is typical.

When time standards are set, performance improves to an averageof 85%. This is a 42% increase in performance:

85 % - 60 %------------------ = 42% performance increase.

60%

Incentive systems can improve performance even further.

Incentive system performances average 120%, that is another42% increase in performance:

120% - 85%

---------------------- = 42% performance increase.85%

Manufacturing plants with no standards average 60% performance.

Manufacturing plants with time standards average 85% performance.

Manufacturing plants with incentive systems average 120% performance.

If additional production output is required, dont buy moremachinery, dont add a second shift, and dont build a new plant.

Just establish a motion and time study program.


14/26

29/11/2011

14

Motion and time study is considered to be the backbone of industrial engineering,industrial technology, and industrial management programs because theinformation that time studies generate affects so many other areas, including thefollowing:

1. Cost estimating2. Production and inventory control3. Plant layout4. Materials and processes5. Quality

. aety

Motion study comes first before the setting of time standards. Motion study is adetailed analysis of the work method in an effort to improve it.

Motion studies are used to

1. Develop the best work method.2. Develop motion consciousness on the part of all employees.3. Develop economical and efficient tools, fixtures, & production aids.

4. Assist in the selection of new machines and equipment.5. Train new employees in the preferred method.6. Reduce effort and cost.

Motion study is for cost reduction, and time study is for costcontrol. Motion study is the creative activity of motion and timestudy.

Motion study is design, while time study is measurement.

Once the importance of motion and time study is understoodand accepted, the techniques of motion and time study are

.

Flow diagramsMulti activity chartsOperation chartsFlow process chartsProcess chartsOperations analysis chart

Work station designMotion economyFlow patternsPredetermined time standards system (PTSS).

Thetechniques of time study start with the last motionstudy technique,whichshows the close relat ionship between mot ion study and t ime study. Thetechniquesof time studyare:

1.Predetermined time standards system (PTSS)2.Stopwatch time study3.Standard data formula time standards4.Work sampling time standards5.Expert opinion and historical data time standards.

WHAT IS A MOTION STUDY?

Motion studies are performed to eliminate waste. Before any improvement inquality or quantity of output, any study of operations time, any scheduling ofwork or balancing of workload or any calculation of standard time,a study ofthe current and proposedmethod is required.

Studies of overall factoryflow or process,called macromotion studies, andthenadditional studies of detail or operations, called micromotion studies, shouldbecompletedfor a project.

Motion studies were conducted by Frank and Lillian Gilbreth about a centuryago in a search for the one best way. It is important to note that such studiesseek to minimize and simplify manual efforts.

Macromotion Study

Any process can be studied by dividing it into process activity. Althougheach activity is different, depending on the product, there are fiveclasses of activities that are included i n all processes. Savings, may befound in the process by reorganizing act ivities.

These activities found in ever se uence of rocesses are

Operations Changes in the properties of the product

Transportations Changes in the location of the product

Inspection Confirmation that change fits to specification

Delay Wait for start of operation, transportation, or inspection

Storage Wait until needed

When the process is first studied, each activity is recorded andarranged into one of the five classes. All observed acti vities arerecorded, and activities not done are not recorded. The purpose ofeach activity should be studied.


15/26

29/11/2011

15

Typically, the questions Who? What? Where? When? Why? and How? must beanswered. Next, each event is observed in the following sequence:

Can the activity be eliminated? If not,

Can the activity be combined and done with another activity? If not,

Can the activity be rearranged so occur in the sequence at an easier time? If not.

Can the activity be simplified with shorter distances, mechanical assist, or reducedcomplexity?

Once these questions are asked and the improvement sequence is defined, it isnecessar to draw a chart or dia ram that shows the motion im rovements.

Process Flow Plan A plan-view plant layout with activities overlaid

Process Operations Chart The sequence of serial and parallel operations

Process Chart All serial activities on a preprinted form

Flow Process Chart All serial and parallel activities on a single page

Work Cell Load Chart A plan view with repetitive operations

Route Sheet A planning tool for scheduling operations

Micromotion Study Considerable wasted motion and idle time can occur within an operation. This time

cant be found with macromotion studies because is usually within one processoperation. The improvement is gained from reducing the operation cycle time.

WHAT IS A TIMEWHAT IS A TIMESTANDARD?STANDARD?

The definition of a time standard is the time required to producea product at a work station with the following three conditions:

(1) a qualified, well-trained operator,

(2) working at a normal pace,

(3) doing a specific task.

These three conditions are essential to the understanding of timestudy.

The importance of time standards can be shown by the threestatistics 60%, 85%, and 120% performance.

The time standard is one of the most important pieces ofinformation produced in the manufacturing department. It is usedto develop answers for the following problems:

WHAT IS A TIME STANDARD?WHAT IS A TIME STANDARD? Continue..Continue..

Determining the number of machine tools to buy

Determining the number of production people to employ

Determining manufacturing costs and selling prices

Scheduling the machines, operations, and people to do the job and deliver ontime

Determining the assembly line balance, determining the conveyor belt speed,oa ng t e wor ce s w t t e correct amo unt o w or , an aancng t e wo rcells

Determine individual worker performance and identifying operations that arehaving problems so the problems can be corrected

Paying incentive wages for outstanding team or individual performance

Evaluating cost reduction ideas and picking the most economical method basedon cost analysis, not opinion

Evaluating new equipment purchases to justify their expense

Developing operation personnel budgets to measure management performance.

How would you answer the following questionsHow would you answer the following questionswithout time standards?without time standards?

How Many Machines Do We Need?

One of the first questions rose when setting up a new operation orstarting production on a new product is how many machines do weneed? The answer depends on two pieces of information:

a. How many pieces do we need to manufacture per shift?

b. How much time does it take to make one part? (Time standard)

EXAMPLE

1. The marketing department wants us to make 2,000 wagons per 8-hour shift.

2. It takes us 0.400 minutes to form the wagon body on a press.

3. There are 480 minutes per shift (8 hours/shift x 60 minu tes/hr).

4. - 50 minutes downtime per shift (breaks, clean-up, etc.)

5. There are 430 minutes per shift available @ 100%.

6. @ 75% performance (based on history) (0.75 x 430 = 322.5).

7. There are 322.5 effective minutes left to produce 2,000 units.

322.5

8. ---------------- = 0.161 minutes per unit, or 6.21 parts per minute.

2,000 units


16/26

29/11/2011

16

The 0.161 minutes per unit is plant rate. Every operation in theplant must produce a part every 0.161 minutes; therefore, howmany machines do we need for this operation?

Time standard = 0.400 minutes/unit

----------------------------------------------------- = 2.48 machines

Plant rate = 0.161 minutes/unit

This operation requires 2.48 machines. If other operations arerequired for this kind of machine, we would add all the machinerequirements together and round up to the next whole number.

In this example, we would buy three machines. (Never rounddown on your own. You will be building a bottleneck in yourplant.)

How Many people should we hire?

Look at the operations chart shown in Figure 4 -1.

From a study of this chart, we find the time standard (or everyoperation required to fabricate each part of the product and each

product.

In the operation shown here (casting the handle), the 05 indicates theoperation number. Usually, 05 is the first operation of each part. The500 is the pieces per hour standard. This operator should produce500 pieces per hour. The 2.0 is the hours required to produce 1,000pieces. At 500 pieces per hour, it would take us 2 hours to make1,000. How many people would be required to cast 2,000 handlesper shift?

Not many people, departments, or plants work at 100% performance.How many hours would be required if we work at the rate of 60%, 85%, or120%?

4 hours 4 hours 4 hours----------- = 6.66 hours; ------------- = 4.7 hours; -------------- = 3.33 hours.

60% 85% 120%

Look again it use operations chart shown in Figure 4-1. Note the total138.94 hours at the bottom right side. The operations chart includes everyoperation required to fabricate, paint, inspect, assemble, and pack out aproduct. The total hours is the total time required to make 1,000 finishedproducts.

In our water valve factory, we need 138.94 hours at 100% to produce 1,000water valves. If this is a new product, we could expect 75% performanceduring the first year of production. Therefore,

138.94 hours per 1,000---------------------------------- = 185 hours/1,000 where 75% = 0.75

75% performance


17/26

29/11/2011

17

The marketing department has forecasted sales of 2,500 watervalves per day. How many people are needed to make water valves?

185 hours/1,000 X 2.5 (1,000) = 463 hours/day needed.

463 / 8 = 57.87 which is e ual to 58 eo le.

Management will be judged by how well it performs to this goal.

If less than 2,500 units are produced per day with the 58 people,management will be over budget, and that is not good.

If it produces more than 2,500 units per day, management is judged

as being good at managing, and the managers are promotable.

Frame Work for FacilitiesPlanning

[Q. Lee, IIE Solution, 1997]Layout or space planning involves five levels -

from the global maps of site location to

engineering drawing tools and workstations

66

Level 1: Global site location

Level 2: Supra-space plan

Level 3: Macro-space plan

Level 4: Micro-space plan Level 5: Sub-micro-space plan

LEVEL 1: Global site locationLEVEL 1: Global site location

The firm decide where to locate facilitiesand determine their missions

The most strategic impact

Major considerations: labor rates, tax break,

67

labor skill and attitudes, supporting services,politics,etc.

Appropriate planning results in facilitiesoptimized for the markets and located nearthe most important resources

68


18/26

29/11/2011

18

LEVEL 2: SupraLEVEL 2: Supra--space planspace plan

Site planning, including number, size,

location of buildings, as well as roads,

water, gas, and rail

69

nvo ve a ser es o raw ng s ow ng

past, present and future configurations

Planning still has long-term and far

reaching consequences

70

LEVEL 3: MacroLEVEL 3: Macro--space planspace plan

A macro-layout, plans each building,

structure, or sub-unit of the site

The designers define and locate operating

71

flow

Easier to correct than site level decisions

A poorly planned facility can bring high

handling cost, confusion, and inflexibility

72


19/26

29/11/2011

19

Level 4: MicroLevel 4: Micro--space planspace plan

Department or cell layout

Location of specific equipment is determined

Emphasis shifts from gross material flow to

73

personal space and communication

Socio-technical considerations dominate

74

LEVEL 5: SubLEVEL 5: Sub--micromicro--space planspace plan

Workstation design

Workstations are designed for efficiency,

effectiveness, and safety

75

Tools-jig and fixture

Location of materials

Appropriate material handling aids

76


20/26

29/11/2011

20

Facilities planning is a complex and broad subject thatcuts across several specialized disciplines (civil,electrical, industrial, mechanical, etc)

new hospital

Facilities PlanningFacilities Planning[Tompkins, et.al. 2003][Tompkins, et.al. 2003]

77

existing warehouse

baggage department of an airport.

Facilities planning determines how an activitys tangiblefixed assets best support achieving the activitys

objective.

Facilities Planning HierarchyFacilities Planning Hierarchy

Facility System

It is important to realize that the term facilities

planning is not synonyms with facilities location,

facilities design, facilities layout, or plant layout.

78

FacilitiesPlanning

FacilitiesDesign

Handling SystemsDesign

Layout Design

DesignLocation

Facilities location - placement with respect tocustomer, suppliers, and other facilities withwhich it interfaces.

Influences of Plant location :

Facilities LocationFacilities Location

79

Markets

Transportation systems

Economic development programs (financialincentives)

Facilities design consists of the facility systems, thelayout, and the handling system Facility system structural systems, the atmospheric systems,

the enclosure system, the lighting/electrical/communicationsystems, the life safety system and the sanitation system.

La out consists of all e ui ment, machiner , and furnishin s

Facilities DesignFacilities Design

80

within the building envelope.

Handling system consists of the mechanisms needed tosatisfy the required facility interactions.

Material handling is very important to the facility designactivity. The choice of material handling equipment willgreatly effect the appropriateness of the facility design.


21/26

29/11/2011

21

Facilities PlanningFacilities Planning

Facilities planning involves making strategic

decisions concerning the tangible fixed assets used

in the production process.

The difference in the planning horizon for each of

81

the different levels of analysis used in the

production process listed in Table 1.1.

Table 1.1: Planning Horizon Associated withTable 1.1: Planning Horizon Associated withProduction AnalysisProduction Analysis

Planning Horizon Level of Analysis

Months-Years Facilities Planning

Months-Years Product Design and Process Planning

82

Weeks-Months Production Planning

Hours-Weeks Production control

Minutes-Hours Quality control

Seconds-Minutes Machine-level real-time control

Motivation Behind Facility PlanningMotivation Behind Facility Planning1. One of the most effective methods for increasing

plant productivity and reducing cost is to reduce oreliminate all activities that are unnecessary orwasteful. A facilities design should accomplish thisgoal in terms of material handling, personnel and

83

equ pment ut zat on, re uce nventor es, anincreased quality.

2. Employee health and safety

3. Energy conservation

4. Community considerations, fire protection, security,and the ADA of 1989

Objectives of Facilities PlanningObjectives of Facilities Planning Improve customer satisfaction by being easy to do

business with, conforming to customer promises, andresponding to customer needs.

Increase return on assets (ROA) by maximizing inventoryturns, minimizing obsolete inventory, maximizing

employee participation, and maximizing continuous

84

improvement.

Maximize speed for quick customer response.

Reduced costs and grow the supply chain profitability

Integrate the supply chain through partnership andcommunication.


22/26

29/11/2011

22

Objectives of Facilities PlanningObjectives of Facilities Planning Support the organizations vision through improved

material handling, material control, and goodhousekeeping.

Effectively utilize people, equipment, space, and energy.

Maximize return on investment (ROI) on all capital

85

expen tures

Be adaptable and promote ease of maintenance.

Provide for employee safety and job satisfaction.

Provide flexibility to adapt to changing conditions

Significance of Facility DesignSignificance of Facility Design

Material handling costs:

30-75% of a products cost (Sule 1991)

20-50% of a manufacturing companys

86

operating budget (Tompkins & White, 1994)

Optimal Layout Design can reduce

production costs

Facilities Planning ProcessFacilities Planning Process

By applying the engineering design approach,a systematic approach can be developed Define the problem

Define (or redefine) the objective of the facility

87

performed in accomplishing the objective

Analyze the problem

Determine the interrelationships among allactivities

Determine the space requirements for all activities

Generate alternative facilities plans

Facilities Planning ProcessFacilities Planning Process

Evaluate the alternatives

Evaluate alternative facilities plans

Select the preferred design

Select a facilities plan

88

Implement the design

Implement the facilities plan

Maintain and adapt the facilities plan

Redefine the objective of the facility


23/26

29/11/2011

23

Developing Facilities Planning StrategiesDeveloping Facilities Planning Strategies

Productdevelopment anddesign decisions

Processing &

ProductionPlanning &

Inventory ControlHuman Resources &

Finance

89

a e r aRequirements

Layout & MaterialHandling # &

Location

Storage,movement,protection &control ofmaterial

Space &Flow

Size &Design

Sources of Information ForSources of Information ForManufacturing Facilities DesignManufacturing Facilities Design

All the information that is used must come

from different sources.

90

,

actually produced by the facility designer.

Some companies have several sub-

departments within manufacturing/industrial

engineering. But, in smaller organizations youare responsible for producing the information.

Sources Of Information ForSources Of Information ForManufacturing Facilities DesignManufacturing Facilities Design

Marketing

Product design

91

Management policy

Marketing

Selling price

Volume, how many can we sell?

92

,

Replacement parts, older products


24/26

29/11/2011

24

Product DesignProduct Design Product design

blueprints

bill of material (part list) indented BOM

buyouts/fabricate

93

assem y raw ngs Part and assembly drawings are especially helpful in

visualization of how parts will fit together

model shop samples (prototypes)

Relationship between FD and product design is

important

Management PolicyManagement Policy Management policy - refers to the upper-level

employees inventory policy (Just in Time, Kanban, WIP)

lean thinking

94

startup schedule

make or buy decision (new or old facility, capitalinvestment, and mission)

feasibility studies (what product or process

proposal is the most profitable for the company

Types of Layout ProblemsTypes of Layout Problems

Service systems layout problems

Manufacturing layout problems

95

Warehouse layout problems

Nontraditional layout problems

Service Systems Layout Problems

Examples: layouts of the tables, kitchen, and cocktail

lounge in licensed restaurant; an insurance office;

runway at an airport; emergency facilities in a

hospital and town; public library

To develop service systems layout, designers must

know the number of entities or facilities that are to

be located, the area that will likely be occupied by

each, the interaction between facilities, and special

layout restrictions for any facility or pair of facilities

General office structures: 1) Closed, 2) Semiclosed,

3) Open, and 4) Semiopen


25/26

29/11/2011

25

Service Systems Layout Problems Service Systems Layout Problems

Manufacturing layout problemsManufacturing layout problems

Layout design is an important task when a

manufacturing systems is redesign, expanded, or

designed for the first time

The layout problems involves determining the

location o machines, workstations, rest areas,

inspection stations, clean rooms, heat treatment

station, supervisor or manager offices, tool cribs,

and other facilities to achieve these five objectives:

Minimize cost of transportation between

facilities


Minimize cost of transportation between facilities

Facilitate the traffic flow

Increase employee morale

Minimize the risk of in ur to ersonnel anddamage to property

Provide for supervision and face-to-face

communication


26/26

29/11/2011


101

Warehouse layout problemsWarehouse layout problems

A good warehouse layout should use

available storage space effectively to

minimize storage and material handling cost

Some factors to be considered in

warehouse design are shape and size of

aisles, height of the warehouse, location and

orientation of the docking area, types of

racks to be used for storages, and the level

of automation involved in the storage and

retrieval of commodities

Warehouse layout problemsWarehouse layout problems

RI-1504/PF/SEW/2004/#1 103

Fulfill Order

Documents

Transcript of Fulfill Order