Organizing Production Equipment

1. Organizing Production Equipment Richard A. Wysk IE450

2. Agenda • What makes for good organization? • Part families • Manufacturing cells Read Chapter 18 on the web

3. Types of Manufacturing Layout • Process Layout • Product Layout • Cellular Layout

4. FUNCTIONAL LAYOUTS ARE INEFFICIENT Drilling Milling Lathe D D L M L M D D L L M M Grinding G L L M G M Assembly G G L L A A G G A Receiving and Shipping A PROCESS-TYPE LAYOUT

5. Process Layout Characteristics • Advantages • Deep knowledge of the process • Common tooling and fixtures • Most Flexible -- can produce many different part types • Disadvantages • Spaghetti flow -- everything gets all tangled up • Lots of in-process materials • Hard to control inter-department activities • Can be difficult to automate

6. L G G L M PRODUCT LAYOUT G D Part #1 M L A A Receiving Part #2 D M L Shipping Part #3

7. Product Layout Characteristics • Advantages • Easy to control -- input control • Minimum material handling -- frequently linked to the next process • Minimal in-process materials • Can be more easily automated • Disadvantages • Inflexible -- can only produce one or two parts • Large setup • Duplicate tooling is required for all cells

8. CELLULAR LAYOUT Cell #2 Cell #1 D D M I D I L Cell #3 M M L D L I M

9. S1 S2 S3 S6 S5 S4 U-shaped cells • U-shaped cells avoid constant displacements to the start of the line and solves many of the island distribution problems.

10. Cellular Layout Characteristics • Advantages • Control is simplified • Common tooling and fixtures • Flexible -- can produce many different part types - a part family?? • Disadvantages • Setup ?? • Need to know about many different processes

11. HIGH FLEXIBILITY TRANSFER LINE PRODUCTION CAPACITY SPECIAL SYSTEM FLEXIBLE MANUFACTURING SYSTEM VOLUME MANUFACTURING Cells STD. AND GEN. MACHINERY LOW HIGH VARIETY

12. How are Cells Formed • Good intuition • Careful study • Group Technology (GT) • Production Flow Analysis (PFA)

13. Production Flow Analysis • A technique for forming part families based on Operation Routing Summaries • Several methods available. We will discuss 2 algorithms for PFF (Part Family Formation)

14. Let’s consider 5 parts (n) and 6 machines (m): n = {101, 102, 103, 104, 105} m = {Drill1, Drill2, Mill1, Mill2, Vbore1, Vbore2} = {D1, D2, M1, M2, V1, V2}

15. Operation Routing Summary

16. Create a PFA matrix, Parts 101 102 103 104 105 1 0 1 0 1 Drill 1 0 1 0 1 0 Drill 2 Machines 1 0 1 0 1 Mill 1 = 0 1 0 1 0 Mill 2 1 1 0 0 1 VB 1 0 0 0 1 0 VB 2

17. å i = w 2 m i j " i King’s Algorithm (Rank Order Clustering) Step#1 Calculate the total column weight for each column Generate 2i Machine# (i) i Part# (j) 101 102 103 104 105 2 1 1 0 1 0 1 2 D 1 2 0 1 0 1 0 4 D 2 3 1 0 1 0 1 8 M 1 4 0 1 0 1 0 16 M 2 5 1 1 0 0 1 32 V 1 6 0 0 0 1 0 64 V 2 (wj) Done! Sum: mi,j* 2i 42 52 10 84 42 for each column (wj)

18. å i D 1 1 1 0 0 14 1 D 0 0 0 1 1 48 2 M 1 1 1 0 0 14 1 M 0 0 0 1 1 48 2 V 0 1 1 1 1 28 1 #2. If Wj is in ascending order, go to step #3; otherwise, rearrange the columns to make Wj fall in an ascending order. 105 101 103 101 105 102 104 V 0 0 0 0 0 32 wj 2 10 42 42 52 84 102 103 104

19. Sum: mi,j* 2j for each row (wi) å j = w 2 m i ij " j #3. "i, calculate the total row weight, wi wi 103 101 105 102 104 D 1 1 1 0 0 14 1 D 0 0 0 1 1 48 2 M 1 1 1 0 0 14 1 M 0 0 0 1 1 48 2 V 0 1 1 1 1 28 Generate 2j 1 V 0 0 0 0 0 32 2 2j 2 4 8 16 32 Done!

20. #4. If wi is in ascending order, stop. Otherwise, arrange rows to make Wiascend. 103 101 105 102 104 1 1 1 0 0 D 1 1 1 1 0 0 M M1 1 0 1 1 1 0 V V1 1 0 0 0 0 1 V 2 0 0 0 1 1 D D2 2 V2 0 0 0 1 1 M 2 V2

21. #5 Stop and make Cells and Part families 103 101 105 102 104 1 1 1 0 0 D 1 1 1 1 0 0 M 1 0 1 1 1 0 V 1 0 0 0 0 1 V 2 0 0 0 1 1 D 2 0 0 0 1 1 M 2

22. #5 Stop and make Cells and Part families Part Family #1 Part Family #2 103 101 105 102 104 Cell #1 1 1 1 0 0 D 1 1 1 1 0 0 M 1 0 1 1 1 0 V 1 0 0 0 0 1 V 2 Cell #2 0 0 0 1 1 D 2 0 0 0 1 1 M 2

23. Discussion • Good rectangles mean that you have very distinctive part families • Cell formation • Volume / Floor space • Size of problems • How about King’s algorithm? Will it always work? • Are there problems with it?

24. DIRECT CLUSTER ALGORITHM 101 102 103 104 105 w i 3 1 0 1 0 1 D 1 0 1 0 1 0 D 2 2 1 0 1 0 1 M 3 1 0 0 0 1 0 M 1 2 1 1 1 0 1 V 4 1 0 0 0 1 0 V 1 2 Step #1. For I, calculate the total no. of positive cells in row, i

25. 101 102 103 104 105 w i 4 1 1 1 0 1 V 1 1 0 1 0 1 D 3 1 1 0 1 0 1 M 3 1 0 1 0 1 0 D 2 2 0 0 0 1 0 M 1 2 0 0 0 1 0 V 1 2 3 2 3 3 3 1 Sort rows in descending order of the wi values D1 No Change D2 V1 M2 No Change Done!

26. Step #2. j, calculate the total # of positive cell in each column, j

27. Sort columns in ascending order. 101 102 103 104 105 1 1 1 0 1 V 1 1 0 1 0 1 D 1 1 0 1 0 1 M 1 0 1 0 1 0 D 2 0 0 0 1 0 M 2 0 0 0 1 0 V 2 3 2 3 3 3 Sort Complete!

28. Step #3. For i = 1 to n, move all columns j where mij = 1 to the left maintaining the order of previous rows. Observe Elements of Row 1 102 101 103 104 105 1 1 1 0 1 V 1 0 1 1 0 1 D 1 0 1 1 0 1 M 1 1 0 0 1 0 D 2 0 0 0 1 0 M 2 0 0 0 1 0 V 2 Move Column 105 to the left and push column 104 back

29. For Rows 1,2 & 3: Move the 1’s to the left and push the columns with the zeroes back Observe Elements of Rows 2 & 3 102 101 103 105 104 1 1 1 1 0 V 1 0 1 1 1 0 D 1 0 1 1 1 0 M 1 1 0 0 0 1 D 2 0 0 0 0 1 M 2 0 0 0 0 1 V 2 Move Columns 101, 103 & 105 to the left and push column 102 back

30. Observe Elements of Row 4 101 103 105 102 104 V 1 1 1 1 0 1 D 1 1 1 0 0 1 M 1 1 1 0 0 1 D 0 0 0 1 1 2 M 0 0 0 0 1 2 V 0 0 0 0 1 2 Move Column 102 to the left and push column 101 back

31. Observe Elements of Rows 5 & 6 102 101 103 105 104 V 1 1 1 1 0 1 D 0 1 1 1 0 1 M 0 1 1 1 0 1 D 1 0 0 0 1 2 M 0 0 0 0 1 2 V 0 0 0 0 1 2 Move Column 104 to the left and push column 102 back

32. 104 102 101 103 105 V 0 1 1 1 1 1 D 0 0 1 1 1 1 M 0 0 1 1 1 1 D 1 1 0 0 0 2 M 1 0 0 0 0 2 V 1 0 0 0 0 2 Step #3 Complete!!

33. Step #4. For j = m to 1, move all rows I, where mij = 1 to the top maintaining the order of the previous columns, wij Observe Elements of Columns 101, 103 & 105: No Change can be made!! Observe Elements of Column 102 104 102 101 103 105 V 0 1 1 1 1 1 D 0 0 1 1 1 1 M 0 0 1 1 1 1 D 1 1 0 0 0 2 M 1 0 0 0 0 2 V 1 0 0 0 0 2 Move Row D2 upwards and push row D1 down

34. Observe Elements of Column 104 104 102 101 103 105 V 0 1 1 1 1 1 D 1 1 0 0 0 2 M 0 0 1 1 1 1 D 0 0 1 1 1 1 M 1 0 0 0 0 2 V 1 0 0 0 0 2 Move Row D2 to the top and push row V1 down

35. Observe Elements of Column 104 104 102 101 103 105 D 1 1 0 0 0 2 V 0 1 1 1 1 1 M 0 0 1 1 1 1 D 0 0 1 1 1 1 M 1 0 0 0 0 2 V 1 0 0 0 0 2 Move Rows M2 & V2 upwards and push row V1 down

36. 104 102 101 103 105 D 1 1 0 0 0 2 M 1 0 0 0 0 2 V 1 0 0 0 0 2 V 0 1 1 1 1 1 M 0 0 1 1 1 1 D 0 0 1 1 1 1 Step #4 Complete!!

37. Step #5. If current matrix is the same as the previous, stop; else to go 3.

38. Identify Cells or potential Cells 104 102 101 103 105 D 1 1 0 0 0 2 Cell #1 M 1 0 0 0 0 2 V 1 0 0 0 0 2 V 0 1 1 1 1 1 Cell #2 M 0 0 1 1 1 1 D 0 0 1 1 1 1 Part Family #2 Part Family #1

39. Production Flow Analysis-SCOPE- We learned two (and probably the most common) methods/algorithms for performing a Production Flow Analysis. There are a host of other algorithms and methods which are used in Academics and in the Industry. (contd..)

40. Production Flow Analysis -Organizational View- Production Flow Analysis consists of 5 different analyses: • Company Flow Analysis • Factory Flow Analysis • Group Analysis • Line Analysis • Tooling Analysis

41. Company’s Goals CFA (Analysis) We get a SCHEME for the division of products and components, machines and facilities into factory sets