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Unit 2

Unit 2. Green Manufacturing Information Flow and Planning Tools: Analysis. Typical Production Functions and Flow Areas Product Need and Identification Market Research Forecasting Scheduling Design Purchasing (Supply chain) Prototyping Production Packaging Distribution (Supply chain)

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Unit 2

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  1. Unit 2 Green Manufacturing Information Flow and Planning Tools: Analysis

  2. Typical Production Functions and Flow Areas Product Need and Identification Market Research Forecasting Scheduling Design Purchasing (Supply chain) Prototyping Production Packaging Distribution (Supply chain) Customer

  3. Integrated Production Control Information System • Concept is based on the need to coordinate the plans and control all the way from forecasting demand to shipping products • Typical information relates to: materials, time & attendance recording, process test & measurement, order processing, supervisor terminal, inventories, conveyor control, work-in-progress reports etc.

  4. Communications Within Manufacturing Entities FINANCE & MANAGEMENT PRODUCT DESIGN PRODUCTION ENGINEERIN SALES & PROMOTION MANUFACTURING PLANNING & CONTROL ENGINEERING RELEASE CUSTOMER RECEIVING SUPPLIES DISTRIBUTION PLANT FLOOR QUALITY SHIPPING SUPPORT INTERFACE TO ALL FUNCTIONS

  5. Jacobs et al Chapter 1: Manufacturing Planning and Control MPC system provides information to efficiently manage the flow of materials, efficiently utilize people and equipment, coordinate internal activities with those of suppliers, and communicate with customers about market requirements

  6. Typical MPC Support Tasks • Plan capacity requirement for market needs • Plan for materials to arrive on time • Ensure proper utilization of equipment • Schedule production activities • Track materials, people, customers’ orders... • Communicate with customers and suppliers • Provide information to other functions etc.

  7. The System and the Framework • Front end • Engine • Back end

  8. Manufacturing Planning and Control System

  9. RESOURCE PLANNING SALES & OPERATIONS PLANNING DEMAND MANAGEMENT Enterprise Resource Planning (ERP) System FRONT END MASTER PRODUCTION SCHEDULE DETAILED MATERIAL PLANNING DETAILED CAPACITY PLANNING MATERIAL AND CAPACITY PLANS ENGINE PURCHASING ORDER RELEASE BACK END VENDOR SCHEDULING AND FOLLOW-UP SHOP FLOOR SCHEDULING AND CONTROL (sfc)

  10. Front End • Establishes company objectives for manufacturing planning and control • Demand management encompasses forecasting customer or product demand • Resource planning provides the capacity necessary to produce the required product • Results in master production schedule

  11. Engine • Set of systems for accomplishing detailed material and capacity planning • MRP determines period-by-period plans for all component parts and raw materials required to produce all the products in MPS

  12. Back end • Depicts the execution systems • Single and multiple work centers • Production cells of FMS • Just-in-time • Group technology

  13. The Shop Floor Information Input • Resource status (people, machines, tools, material handling, inspection equipment etc.) • Job status • Material status • Schedule status • Material move status • Recent performance status

  14. Production Control Information Outputs • Requirement planning reports • Inventory control reports • Operations scheduling report • Materials handling reports • Quality control reports • Assembly reports • Shop floor control reports

  15. Production Control Information Flow • The status of materials as they progress from one operation to the other needs to be monitored for efficient, smooth and bottleneck free movement in the factory • The controlling activity of management is accomplished through the information system that monitors the production activity

  16. Jacobs et al Chapter 2: Enterprise Resource Planning (ERP) Enterprise resource planning is a term that describes a software system that integrates application programs in finance, manufacturing, logistics, sales and marketing, human resources, and the functions and data processing applications in a firm.

  17. How ERP Connects the Functional Units

  18. Some Analytical and Management Tools Employed in Green Manufacturing • MRP & MPC Systems • Scheduling Tools • Equipment, facility, personnel, process, material, energy and product analysis/auditing tools • Process Charts • Operation process Charts • Flow Diagrams • Product Costing Software • Mathematical Models • Forecasting Models • Spreadsheet such as Excel • Most Quality Control Tools • Simulation Tools such as Simprocess

  19. RPM = Feed rate = Volume = Areas of circles, rectangles, triangles etc = Perimeter = Circumference = Punch force = Shear force = Press force = Robot justification = Takt time = Summary of route sheet = Machine requirement = EOP = Forecasting models = Scheduling models = Probability of events = Mean = Standard deviation = Forging force = Break-even analysis = Sample Analytical Model Areas

  20. RPM RPM = Speed x 4/D or (cutting speed * 12)/ (Pi* Diameter)

  21. Feed Rate • Feed rate = RPM x T x CL Where: • FR = the calculated feed rate in inches per minute or mm per minute. • RPM = is the calculated speed for the cutter. • T = Number of teeth on the cutter. • CL = The chip load or feed per tooth. This is the size of chip that each tooth of the cutter takes.

  22. cube = a3 rectangular prism = abc irregular prism = bh cylinder = bh = pir2h pyramid = (1/3)bh cone = (1/3) bh = 1/3pir2h sphere = (4/3)pir3 ellipsoid = (4/3)pi r1r2r3 Volume Calculations

  23. Punch Force Punch force = F = 0.7TL(UTS)

  24. Shear Force • Shear force = F = K * Q * t * lultimate • Where Q=perimeter; t=thickness; lultimate=ultimate shear strength; K=1.3)

  25. Forging Force • Forging force = Pressure X Width XDepth

  26. Bending Force Bending force = P = (UTS)LT2/W

  27. Z Score Standard scores or z scores are computed as

  28. Robot Justification • Justifying a robotic system is performed using this model: • [P = I/(S-E)] • P = # of years for pay back • I = Investment in robot • S = Savings in robot • E = Cost of servicing the robot

  29. Takt Time • Takt time is determined by dividing the daily allotted time by the daily number of required units. • For example, if the daily allotted time for producing 1000 stools is 420 minutes, then takt time will be as follows: • Takt time = 420/1000 = 0.42 minute/unit

  30. Economic Order Quantity • An inventory-related equation that determines the optimum order quantity that a company should hold in its inventory given a set cost of production, demand rate and other variables. This is done to minimize variable inventory costs. • where :  S = Setup costs D = Demand rate P = Production cost I = Interest rate

  31. Workstation and Machine Requirements • Summary of route sheets • Machine requirements or total number of each type of machines needed • Takt time (R value) of your product • Conveyor speed

  32. Summary of route sheets Part name Left roll Right roll Axle________ Time Standards in Pieces Per Hour Parts per unit 1 1 1 Operations Turning lathe _______ _______ _______ Drill lathe _______ _______ _______ Threading lathe_______ _______ _______ Knurling lathe _______ _______ _______ Tip: Match your estimated time from route sheet with those of Time Standards in Pieces Per Hour

  33. Time Standards in Decimal Minutes Per Unit Left roll Right roll Axle_____ Turning lathe _______ _______ _______ Drill lathe _______ _______ _______ Threading lathe _______ _______ _______ Knurling lathe _______ _______ _______ Tip: Divide your Adjusted Minutes by Time Standard’s Pieces Per Hour

  34. Machine requirements spreadsheet Part name Left roll(1) Right roll(1) Axle(1) Total______ Machines Turning lathe _______ _______ _______ _______ Drill lathe _______ _______ _______ _______ Thread lathe _______ _______ _______ _______ Knurling lathe _______ _______ _______ _______ _________________________________________________________________ Tip: Divide your Time Standards in Decimal Minutes per Unit by Takt Time

  35. Forecasting Model:Moving Average Example Sales for period 7 would be the average of the previous six periods: Or 10000+12000+9000+11000+9600+12100= $10617

  36. Forecasting Model:Trend Enhancement of the basic Exponential Smoothing ESFt-1 + (actual demandt - ESFt-1)

  37. Forecasting Model: Trend enhancement of the basic exponential smoothing • TEFt = Base valuet-1 + Trendt-1 • Base value = (actual demandt) +(1 – ) (Base valuet-1 + Trendt-1) • Trendt = (base valuet – base valuet-1) + (1 – )(Trendt-1) •  = Base value smoothing constant •  = trend smoothing constant • t = current time

  38. Forecasting Model:Trend enhancement of the basic exponential smoothing

  39. Bill of Materials (BOM) Part Part Number Description Material Cost NumberNameNeededor SizeEach($) 30431 Frame 1 6” X 9” Aluminum 15 34572 Base 1 12” X 23 Aluminum 20 90321 Handle 1 3/8R X 7” Steel 14 36780 Knobs 2 1/4R X .5” Steel 5 76645 Gear 1 1.125R X 3.5” Steel 7 65736 Rack 1 ½” X ¾” X 7” Steel 12 10839 Press head 1 ½”R X ½” Steel 4 98600 Swivel tube 1 ¾”R X 2.5” Steel 5 Total ____ ____

  40. Probability of Events • The probability of event A is the number of ways event A can occur divided by the total number of possible outcomes. It is expressed as: • P(A) =  The Number of Ways Event A Can Occur   The Total Number of Possible Outcomes

  41. Mean, Median & Mode • Determine the mode • Determine the median • Determine the mean • Determine which of the above measures best described the data’s central tendency • Sketch a tally sheet • Sketch the histogram of the distribution Weights of 20 Boxers In Pounds: 152, 156, 153, 150, 151, 158, 151, 152, 159, 161, 152, 158, 156, 153, 151, 153, 155, 154, 153, 157

  42. Standard Deviation • Shows how much variation or "dispersion" exists from the average (mean, or expected value) Determine the SD of the following eight values:

  43. Standard “Z” Value • The standard score of a raw score x is • where: • μ is the mean of the population; • σ is the standard deviation of the population.

  44. The Normal Curve

  45. Control Limits

  46. Elements of the Control Chart . . UCL = CL+ 3s . . . . X . CL = X LCL = CL - 3s 1 2 3 4 5 6 7 Time/Order

  47. Quality • Quality = Q = E/1 • Where E = Expectations

  48. Productivity • Productivity is a ratio of production output to what is required to produce it (inputs) • Productivity = Output / Input

  49. Space Requirement Spreadsheet Machine Length X width Sq Ft X No of Stations Total square Ft Milling Machine 10 X 5 50 X 4 200 Injection Molder 15 X 6 90 X 6 5400 Paint Systems 100 X 30 3000 X 1 3000 Punch Press 6 X 4 24 X 5 120 Assembly 40 X 20 800 X 1 800 Total Square Feet 9520

  50. Thread Calculations

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