MINGGU III-IV

TATA LETAK FASILITAS

Typical Facility Planning Problems
 Plant layout Procedure (1)
1. What will be produced
2. How many will be made
3. What parts will be purchased
4. How each part will be fabricated
5. Sequence of assembly
6. Time standards
7. Plant rate
8. Number of machines needed
9. Balance assembly lines
 Plant layout Procedure (2)
10. Flow requirements (String diagram – Multi-
column process chart – From to chart –
process chart – flow process chart – flow
diagram)
11. Activity relationships
12. Work station layouts
13. Needs for personnel and plant services
14. Office needs
15. Total space requirements
16. Select material handling equipment
 Plant layout Procedure (3)
17. Allocate area
18. Develop plot plan
19. Construct master plan
20. Seek input and adjust
21. Seek approvals
22. Install
23. Startup
24. Follow-up
 1. What will be produced ???
• Product Name: Air Flow Regulator
Product Design
• What Product data required for the facility
design problem ?
Product Design
Product Design
Product Design: Part 001
Product Design: Part 002
Product Design: Parts 010, 011, 012
Product Design: Exploded View
 2. How many will be made ???
• DEMAND  FORCAST  CAPACITY
Product Quantity (how much to produce?)
• Ask important customers : How many unit (products)
do they want to buy?
• Production rate is usually 250 days a year = 50
weeks x 5 working days x 1 shift per day x 8 hours
per shift x 60 min
• if for example annual sales ≈ 250,000 units a year.
Then,
• Production rate per day = 1000 units
 Takt Time and Plant Rate (1)
• 1,000 units per day are needed
• We have 8 hours per shift x 60 min= 480 min
per shift
• Take 10% down time (personal fatigue + delay
time), then 432 min per shift available
• Take 90% efficiency , then 389 min of net time
is available.
 Takt Time and Plant Rate (2)
• production time per unit = 389 min ÷ 1,000
units = 0.389 min per unit = Takt Time
• R= Plant rate = 1/ 0.389 = 2.57 units per min
• This means every workstation and every
machine in the plant will need to produce ≈
2.5 parts per minute.
• If we need two parts (like axles on a toy
wagon) per finished unit, then we would need
5.14 parts per minute
 Example 1:
Final Product

• To satisfy the demand, We want the plant to

operate with …
 Example 1:

• MESIN 1 = 0.40/0.389 = 1.02

• MESIN 2 = 1.50/0.389 = 3.86
• MESIN 3 = 0.80/0.389 = 2.06
 Example 2:
• To satisfy the demand,
We want the plant to operate with …
 Example 2:

• MESIN 1 = 0.40/0.389 = 1.02

• MESIN 2 = 1.50/0.389 = 3.86
• MESIN 3 = 0.80/0.389 x 2 = 4.11
 Scrap and Rework Rates

Ii = Production input to operation (i)

Si = Fraction of (Pi) lost (scrap)
Oi = output of process
Scrap Rates – Series system
 Example (Series System) (1)
• 5 processes in series with losses (scrape %) as given
in table

Market demand estimate is 2000 units out, then

Amount of raw material and processing on

operation 1 is not based on the market
estimate (2000 units) but on (2190 units)
 Example (Series System) (2)
• Summary of production requirements for all
processes:
 Example: Non series System
• Work backward from end of the line.
Exercise: Calculate Inputs (A,B,C,D)
What parts will be purchased ??
Process Design
1. Process Flow charts
2. Make vs. Buy
3. Parts Lists
4. Bill of Materials
5. Route Sheets
6. Assembly Charts
7. Operations Process Charts
Process Flow Chart
Process Flow Chart
Make or Buy Decisions?
• "Make" or "buy" decision is part of a process planning function.
"Make" or "buy" decisions are typically managerial decisions
requiring input from finance, industrial engineering, marketing,
process engineering, purchasing and human resources
 Parts list includes the following
• Part numbers
• Part name
• Number of parts per product
• Drawing references
Material size is the raw material’s stock size per unit for
the make parts
 How each part will be fabricated ??
• Bill of materials
• Bill of materials
• Bill of materials
 ROUTE SHEET
• A route sheet indicates the output of process selection procedure, which
includes:
 Processes (welding, drilling, milling..)
 Equipment (drill press, lathe, CNC machining center)
 Raw materials(steel, cast iron, plastic, aluminum..)
• Sequencing the required processes can be done by three different
methods:
 Assembly chart (Begins with completed product and trace the
product disassembly back to its basic components)
 Operation Processing chart (Superimposes the route sheets on the
assembly charts to see the overview of the flow of processing)
 Precedence diagram (Network representation of a process, that
shows the interactions from the initial time to the final product more
clearly)
ROUTE SHEET
 Workstation Design
Space Requirement
– Work table
– Incoming materials
– Outgoing material (finished product)
– Operator Space (access to equipment)
– Location of waste
– Fixtures and tools
– Scale of drawing
Workstation layout - Example
Workstation layout - Example
Workstation layout - Example
 Machine Requirement
• Let i= operations in part (k) to be performed on
machine (j) for i= 1,2,..., n ; K =1,2,..., m & j =1,2,..., l
Pi = Production rate for operation i (units/hour)
ti = Processing Time per unit for operation (i) (min/hour)
Ei = Efficiency of machine while running
Ri = Reliability of machine (j)
Mj = Number of type (j) machines required
Xj = Set of operations run on machine (j)
 Example
• Three Parts No. (231), (785) and (765) each has
an operation to run on a Horizontal milling
machine (Mj=M2). Takt time is required to be
0.173 min/unit and machine reliability (90%)
and efficiency (98%).
• The 3 operations time(s) are given in (hours) as:
 Example (lanjutan)
• Takt time = 0.173 min/unit , = 0.00288 hour/unit
• Then, Plant rate (Pi) = 5.78 units/min = 346.82
units/hour ≈ 347 units/hour
• For the horizontal milling machine (M2),
 Latihan 1
• Consider the cylindrical part with five surfaces as
shown in figure. The part is required to be produced
in a plant with an annual quantity of 2.5 million
parts, total number of days per year = 250 , one 8
hours shift per day, and with an average 20% time
losses due to breakdowns, efficiencies, etc. The
following manufacturing data has been observed :
 Latihan 1 (lanjutan)
• Calculate the # of machines of each type
 Latihan 2
• A simple Job shop which makes 3 products on
3 machines. The 3 products include 7 parts
with Production Rate in units/hour for each
part as shown in table

Net Available (Productive) time = 55 min with 8 hours

per day , Demand = 12,000 units for each part