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Design of a Flexible Shopfloor Layout for a Fabrication Jobshop

Design of a Flexible Shopfloor Layout for a Fabrication Jobshop. Details about Company X. Fabrication jobshop Unstable part mix Unstable production volumes Variety of customers Variety of materials. Concerns of Company X. High order throughput times High WIP (Work-In-Progress) levels

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Design of a Flexible Shopfloor Layout for a Fabrication Jobshop

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  1. Design of a Flexible Shopfloor Layout for a Fabrication Jobshop

  2. Details about Company X • Fabrication jobshop • Unstable part mix • Unstable production volumes • Variety of customers • Variety of materials

  3. Concerns of Company X • High order throughput times • High WIP (Work-In-Progress) levels • Poor space utilization • Chaotic flows of material in current layout • Absence of aisles

  4. Checklist to Assess the Current Layout • Evaluate existing facility • Identify core problems • Identify areas for improvements • Evaluate new layout to gauge improvements

  5. Employee Feedback on Checklist • Availability of manufacturing equipment • “We are not flexible or efficient” • Inventories • “We are not running what we want to ship today” • Space utilization • “We have the opportunity to use our space better”

  6. Solution Design of a flexible shopfloor layout • Robust layout • Changes in part mix • Changes in production volumes • Facilitate subsequent improvement strategies • Setup reduction • Scheduling

  7. Input Data • Product routings • Sequence analysis chart • Layout drawing • Equipment inventory (Plant List)

  8. Sequence Analysis Chart

  9. Modifications to Sequence Analysis Chart • No BOM structure • Incorporated new processes, ex: HAA • Machine names not unique, ex: TA, BB • Converted TA to TA1, TA2, TA3 • Converted BB to BBa, BBb, BBc, etc. based on machine capabilities

  10. Flexible Configuration for BB BBa = {5,9}  BBc BBb = {5,9}  BBd BBc = {3,4} BBd = {6,7} BBe = {BBf, BBa,b, BBd} BBf = {1, 2, BBc} { } = Primary Machines  = In case of overload, orders get transferred to Secondary Machines

  11. Present Layout

  12. Methodology Samples From-To Chart RobustLayout BlockLayouts MigrationZones

  13. Methodology Samples From-To Chart RobustLayout BlockLayouts MigrationZones

  14. Criteria for Selecting Part Samples • Aggregate • The complete set • Customers • Top 3 in terms of volume • Lucent, ABB, (Ohaus and ITI) • Materials • Top 2 in terms of volume • CRS and AL

  15. Customer Vs. Volume

  16. Start Input data file End of file Y A Stop N Read: Lot size & # of lots/year Flowchart for Computer Program Compute V=(lot size) * (# of lots/yr.) B

  17. B Read: Machine Name Unique Machine Update Unique Machine List Y N Any more machines Y D C N A

  18. C Read: Machine Name Unique Machine Y Update Unique Machine List Update From-To Chart with V D

  19. Block Layouts • Symbolic representation of machines • Relative positions of machines in the shopfloor (7x4 grid)

  20. Optimal Block Layout

  21. Start Create Initial Random Solution All Possibilities Completed? Apply Pairwise Interchange Algorithm N Y Is the Solution Better? N Y Update Best Solution Is User Happy with the Best Solution? N Y Stop Report Best Solution

  22. Aggregate Layout

  23. Layout for Lucent Parts

  24. Layout for ABB Parts

  25. Layout for ITI and Ohaus Parts

  26. Layout based on Aluminum Parts

  27. Layout based on Cold Rolled Steel Parts

  28. Migration Zones of Machines • Region of movement of a particular machine when layouts created for different samples are superimposed. • The smaller the migration zone the more robust the layout. 2 1 3 Migration Zone 4 5

  29. Migration Zones

  30. Migration Zones (contd)

  31. Proposed Layout (1)

  32. Proposed Layout (2)

  33. Proposed Layout (3)

  34. Criteria for Evaluation of Layouts • Material handling cost • Space utilization • Aisle structure • Order throughput times • WIP Levels

  35. Flow Intensity - Current Layout

  36. Flow Intensity - Proposed Layout (1)

  37. Flow Intensity - Proposed Layout (2)

  38. Flow Intensity - Proposed Layout (3)

  39. Benefits of Proposed Layouts • Material Handling

  40. Benefits of Proposed Layouts (contd) • Space reclaimed • New equipment, ex: Laser • New department, ex: Paint Booth • Visual (line-of-sight) scheduling • WIP reduction • Elimination of “junk” equipment

  41. Contributions to Industrial Practice • Multi-sample approach to generating block layouts • Migration zones of machines • Automated generation of From-To chart • Integrated use of STORM and FactoryFlow for optimization support to user of FactoryFlow

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