EIM 227

Manufacturing systems I
By T.Kanyowa
Industrial and Manufacturing Engineering
Classification of Manufacturing Systems

 Project
 Jobbing
 Batch
 Line
 Continous
Business Implications of process choice

 How each business process is affected in terms of the following aspects;

 Products and Markets (product type, range, customer order size, product introductions)
 Manufacturing ( process technology, f;exibility, production volumes)
 Investment & capital investment
 Invetory levels ( raw materials, WIP, finished goods)
 Infrastructure
Hybrid Processes

 Numerical control
 Machining centre
 Flexible Manufacturing Systems
 Group technology
 Mix mode assembly
 Transfer lines
 Multi mode assembly
Facility Layout and Design

 Layout problems are stimulated by the following;

 Product design change
 Introduction of new products
 Changes in volume demand
 Poor worker environment
 Change in location
 Cost reduction
Classes of Plant Layout Problems

 Minor changes in present layout’

 Existing layout rearrangement
 Relocating into existing facilities
 Building a new facility
 N.B Students should be able to highlight objectives of a good plant layput such as
minimize cost, minimize WIP and many more
Layout Types

 Process Layout
 Product Layout
 Cellular Layout
 Fixed Position
 Hybrid
Flow Analysis in Layout Problems

 Flow process chart

 This allows the designer or plant engineer to analyse the flow direction of process in the
pant
 How the processes are interconnected or the major relationships
From To Chart

From To Saw Lathe Drill Mill Inspection

station
Saw 120 576
Lathe 160 528
Drill 96 80 288
Mill 128
Inspection 160
station
Systematic Layout Planning
Steps
Analyse product flow
Identify and include non-flow factors
Assess data and arrange work areas
Determine space arrangement
Fit space arrangement into available space
Possible Tools
From to chart
Activity relationship chart (REL)
Activity arrangement diagram
Space relationship diagram
Floor plan detailed layout modes
Potential Criteria for evaluation of layouts

 Possible layout performance measurement ratios;

 DLMH = DLMHD/DL
 Direct labour material handling ratio = direct labour material handling ($)/direct labour
(people)

 SSV = OSS/TSS
 Storage space utilization = storage space occupied by materials/total storage space

 ASP = AS/TS
 Aisle space proportion = Aisle space/Total space

 Mo = M/O
Simple Facility Location

 For straight line or Euclideab distance

 d (X, Pi) = √(x –a)^2 + (y-b)^2
 Where x and y are coordinates for the new facility and a and b are for the existing facility i

 For rectangular or rectilinear movement

 d (X, Pi) = │x - a│ + │y -b│
 Transportation costs are assumed to be a function of distance
 f(X) = ∑(Lk * Ri + Ck *Ri * d(X, Pi)
 Lk ~ load/unload staion
 Ri~ number of trips per period to facility I
 Ck~ transportation cost index
Workout example of a simple facility layout

 With the reference to table below customers 1 to 6 can be saved from either location
A(30,30) or B( 80,60). Given that the load/unload cost per trip Lk = $1 and the cost per
unit distance Ck = $0.001/m for all customers 1 to 6. Which is the best location in terms of
cost.
Example continued

Customer X y No of trips Measurement

type
1 40 60 185 Rectilinear
2 50 20 300 Rectilinear
3 60 40 150 Rectilinear
4 80 40 205 Straight line
5 40 40 200 Straight line
6 60 60 175 Straight line
Pairwise Exchange Method

Material Flow Matrix

To Dept 1 2 3 4
From dept 1 - 10 15 20
2 - 10 5
3 - 5
4 -
Pairwise Exchange Method Cntd

Distance Matric based on existing layout

NB The pairwise iteration method simply states that for each iteration all feasible exchanges in the location of the dept pairs are evaluated and the pair that results in the largest reduction in total cost is selected . Since all depts. Are assumed to be equal size, the feasible exchanges are 1-2, 1-3, 1-4, 2-3, 2-4 and 3-4

The total cost TC1234 = 10(1) + 15(2) + 20(3) + 10(1) + 5(2) + 5(1) =125

Do the next iteration for TC2134, TC3214, TC4231 and so forth.

To Dept 1 2 3 4
From Dept 1 - 1 2 3
2 2 1
3 2
4