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IENG 471 - Lecture 04 - 2

Schedule Design:
The Sequel

3/12/2018 IENG 471 Facilities Planning 1

Now):  HW: (HW 2)  Product BOM  Product Operation Process Chart  Product Precedence Diagram  Next Assignment:  HW: (HW 3) See Assignment Link  required input for each of the workstations  equipment necessary for each machine  steady state cycle time for each machine  ideal machine assignment for each machine  compute the idle time  unit cost at each workstation  total cost per good unit  square footage for each workstation and the total space required 3/12/2018 IENG 471 Facilities Planning 3 .Assignments  Assignment (Due Today .

Equipment Requirements  Equipment Fractions are the number of machines of one type required to produce the required volume of product(s)  Some machines can be used to perform multiple operations…  So. then fewer total machines may be required!  Some machines may not be able to perform the required operation(s) fast enough to reach the required volume with only one machine…  So. more copies of the machine may be required! 3/12/2018 IENG 471 Facilities Planning 4 . if idle time on the machine exists. and there are multiple products scheduled.

expressed as % of the “up time” that the machine is available to work (%H) 3/12/2018 IENG 471 Facilities Planning 5 . expressed as a percentage of the standard operation time  H is the hours available for production on the machine during the shift (or whatever unit of time matches parameter S)  R is the availability (reliability*) of the machine.Estimating Equipment Fractions  The equipment fraction for each req’d machine is based on all of the operations the machine will perform  Good thing we got those Operations Process Charts!  To find the number of machines of a type for the facility:  The number of workstations for a shift (F) is: SQ F where: EHR  S is the standard time to perform the operation. per unit  Q is the quota of output units per shift  E is the efficiency of production on the machine.

Reliability  Reliability is a measure of how often a system fails:  How long (on average) you can run it until it stops working right  How do you know that it’s not working right?  MTTF (Mean Time To Failure) or  MTBF (Mean Time Between Failures) 3/12/2018 IENG 471 Facilities Planning 6 .

Maintainability  Maintainability (serviceability) is a measure of how long it takes to return the system to proper operation:  Sum of the times required to:  diagnose the problem  obtain repair parts / tools  repair the failed components  return the unit to operating conditions  MTTR (Mean Time To Repair) 3/12/2018 IENG 471 Facilities Planning 7 .

Availability  Availability is a function of Reliability and Maintainability:  It is the percentage of time that you can count on using it for production  % Availability = MTTF MTTF + MTTR 3/12/2018 IENG 471 Facilities Planning 8 .

No.Equipment Fractions . Fraction Ceiling  The lower bound on the number of machines 0109 1.6 1 the ceiling values for each operation… Total  But … 4 6 Req’d 3/12/2018 IENG 471 Facilities Planning 9 . Integer machines is an integer Op.1 2 required is 4 – the sum of the equipment fractions 0206 2.continued  Since the number of Equip.3 3  The upper bound on the number of machines required is 6 – the sum of 0274 0.

Equipment Fractions .continued  We should adjust the required number of machines to also account for:  Frequency of changeover (flexibility)  Set-up times  Preventative maintenance  Manufacturing policies…  Therefore. the four machines estimate might not really be feasible … it assumed that everything was best case scenario! 3/12/2018 IENG 471 Facilities Planning 10 .

5% scrap rate  3 grams of rubber needed per foot  Find the number of feet to be processed at each workstation!  Find the raw rubber needed for this process! 3/12/2018 IENG 471 Facilities Planning 11 .Ex: Injection Mold Rubber Feet  Process for juicer is:  Mold & trim feet – 2% scrap rate  Transport trimmed feet to line – 1% scrap rate  Assemble juicer – 0.

7 min to fix. 18 min to re-warm  Run one shift per day  Obtain one set of four feet per cycle  Cycle time is 40 s (steady state)  Find the equipment fraction for this process! 3/12/2018 IENG 471 Facilities Planning 12 . and 35 min machine warm-up (to heat the mold and material).Ex: Injection Mold Rubber Feet  Shift is 8 hr. but reduced by two 15 min breaks.  Production schedule requires 2450 sets of feet daily  MTTF is 38 hours  MTTR comprises 5 min to diagnose. 55 min to obtain spare parts.

eliminating daily warm-up time?  An improved facility design reduces the time to get spare parts to 2 min.Questions  What is the machine fraction if. and the re-warm time to 1 min? 3/12/2018 IENG 471 Facilities Planning 13 . instead:  A Manufacturing Engineer suggests using a four unit mold instead of a single unit mold?  An Industrial Engineer suggests running three shifts.