chapter 3-6 fsa

8/8/2019 Chapter 3-6 FSA

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Basic Layout Types and

Activity RelationshipsCHAPTER 6


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Flow and Activity Analysis

Flow Analysis Quantitative measure of movement between

departments or activities.

Activity Analysis Non-quantitative factors that influence the location

of departments or activities.

Analyze the flow ofmaterials, information, equipment,and personnel


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Basic Layout Types

Fixed Product Layout (Sabit rn Tipi Yerleim)

Production Line Layout (retim Hatt Tipi

Yerleim)

Process Layout (Sre Bazl Yerleim)

Product Family Layout (rn Ailesi TipiYerleim)


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Fixed Product Layout

lathe

press

welding

paint

Rawmaterials

roduct


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Fixed Product Layout

Production is executed at a fixed location; materials,equipment, and personnel flow into this location.

This type of layout is usually required by the nature of theproduct

Advantages Material movement is reduced An individual can complete the whole process Highly flexible; can accommodate any changes in design

Disadvantages Personal and equipment movement is increased Risk of duplication of equipment Requires greater worker skills Not suitable for high production volumes


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Production Line Layout retim Hatt Tipi Yerlesim

The product flows through an assembly line while the personnel andequipment movements are limited

Customer, Material,

or Components

Finished

Goods

MaterialsAnd/orWorkforce

WS

1

Suitable for Repeated and Continuous Processes

WS

2

WS

3

WS

4





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Production Line Layout

The product flows through an assembly line while thepersonnel and equipment movements are limited

Advantages High Production Rate Low per unit cost High machine/worfkforce utilization Lower material handling costs Less personnel skill is required Lower Work-In-Process Inventory (WIP)

Disadvantages

High machine utilization is risky Process performance depends on the bottleneck operation May not be flexible enough for product design, volume changes Decreased employee motivation Huge investment is required


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Process Layout

lathe lathe

lathe

mill mill

mill

mill

mill

drill

drill

grind

grind

ssemble

ssemble

ssemble

ssemble

ssemble

ssemble

paint

paint

paint

paint

ST

ORAGE


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Process Layout Sre Bazl Yerleim

Similar/Same processes are grouped together.

Advantages General purpose equipments can be used

General purpose equipments are cheaper Robust against machine breakdowns Robust again design, volume changes

Disadvantages

Material handling requirements are increased Increased WIP Difficult to schedule the jobs Higher skills are required Difficult to analyze the process performance


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Product Family - Group Layout; Cellular Layout -rn Ailelerine Gre Yerleim; Hcresel Yerleim

Parts are grouped based on common processing sequences, shapes,compositions, and/or so on. Product families are called pseudo-products.For each group (or pseudo-product) a manufacturing cell is designed

-1111 -1111

222222222 - 2222

Monta

j

3333333333 - 3333

44444444444444 - 4444

Torna

Torna

Dvme

Dvme

Pres

Pres

Matkap

Matkap

Matkap

Isllem

Isllem

Isllem

DiAma

DiAma

Tala.

Tala.


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Product Families


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Product Family Layouts are like acombination of Production Line Layoutsand Process Layouts

Advantages Cradles benefits of product and process layouts

Disadvantages Balancing manufacturing cells are difficult and

unbalanced cells may increase WIP

Product Family - Group Layout; Cellular Layout -rn Ailelerine Gre Yerleim; Hcresel Yerleim


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Constructing Manufacturing Cells(malat Hcrelerinin Oluturulmas)

In product family layout types machines are groupedtogether to form manufacturing cells

Manufacturing cells implementation includes: Selection (seim) Design (tasarm) Operation (operasyon) Control (kontrol)

We are interested in the selection process whichclusters machines into cells BEA, ROC, ROC2, DCA, CIA, LCC,


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DCA Direct Clustering AlgorithmDirekt Kmeleme Algoritmasi

Step 0: Construct part-machine matrix(para-makine matrisi)

Machine #

Part # 1 2 3 4 5# of 1s

1 1 1 2

2 1 1

3 1 1 1 3

4 1 1 2

5 1 1

6 1 1 2

# of 1s 3 2 2 2 2


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DCA

Step 1: Order the rows from top to bottom in descending ordersof number of 1s and order the columns from left to right inascending orders of number of 1s. Break ties in descendingnumerical sequenceMachine #

Part # 5 4 3 2 1# of 1s

3 1 1 1 3

6 1 1 2

4 1 1 2

1 1 1 2

5 1 1

2 1 1

# of 1s 2 2 2 2 3


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DCA

Step 2: Sort the columns. Start with the first row and move thecolumns with 1 in the first row to as left as possible. Continuewith the following rows until no further shifting is possible.

Machine #

Part # 5 4 2 3 1# of 1s3 1 1 1 3

6 1 1 2

4 1 1 2

1 1 1 2

5 1 1

2 1 1

# of 1s 2 2 2 2 3


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DCA

Step 3: Sort the rows. Starting with the left-most column, shiftthe rows up so as to form blocks of 1.

Machine #

Part # 5 4 2 3 1# of 1s

3 1 1 1 3

6 1 1 2

5 1 1

4 1 1 2

1 1 1 2

2 1 1

# of 1s 2 2 2 2 3


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DCA

Step 4: Form cells.

Machine #

Part # 5 4 2 3 1# of 1s

3 1 1 1 3

6 1 1 2

5 1 1

4 1 1 2

1 1 1 2

2 1 1

# of 1s 2 2 2 2 3


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DCA Dealing with Anomalies

Step 4: Sometimes machines cannot be allocated to a single cell

Machine #

Part # 5 4 2 3 1# of 1s

3 1 1 1 36 1 1 2

5 1 1 2

4 1 1 2

1 1 1 1

2 1 1

# of 1s 2 2 2 2 3

Alternative 1:have twomachine 2.

Alternative 2:putmachines 2 and 3

into different cellsbut close to eachother so that part5 can be processedon the boundariesof the cells.


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Measuring Flow

1. Quantitative Flow MeasurementFrom-To Chart (Nerden-Nereye emas)(large volumes moved)

2. Qualitative Flow Measurement ActivityRelationship Chart(Aktivite-liki emas)(low volumes but intensive communication &organizational relationships)

F T Ch t


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From-To ChartProduct A: 1-2-3-4 Production volume = 10Product B: 3-4-2-1-2 Production volume = 20

1 2 3 4

1 2 3 41 10+20=30

2 20 10

3 10+20=30

4 20

From To Chart


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What if Component B is twice as large as Component

A, and thus, moving 2 units of A is equivalent tomoving 1 unit of B

Using Component Aas the referenceproduct

1 2 3 4

1 10+20=30

2 20 10

3 10+20=30

4 20

1 2 3 4

1 10+40=50

2 40 10

3 10+40=50

4 40

From-To Chart

From To Chart


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Alternatively,

Using Component Bas the reference

product

1 2 3 4

1 10+20=30

2 20 10

3 10+20=30

4 20

1 2 3 4

1 5+20=25

2 20 5

3 5+20=25

4 20

From-To Chart

A ti it R l ti hi Ch t


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Activity Relationship Chart

Assessment of qualitative factors Replaces the from-to chart with a qualitative

closeness rating All pairs of relationship are evaluated and assigned

a closeness rating representing an orderedpreference

A = Absolutely Necessary (Mutlak Gerekli)

E = Especially Important (zellikle nemli)

I = Important (nemli) O = Ordinary Closeness O.K. (Sradan Yaknlk)

U = Unimportant (nemsiz)

X = Undesirable (Tercih Edilemez) A and X > E > I > O > U

All ratings but U are explained with a numeric code

A ti it R l ti hi Ch t


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Activity Relationship ChartConstruction Procedure

1. List all departments or activities to be included.

2. Obtain closeness ratings by interviewing orsurveying persons involved in performing functionswithin each activity, as well as those responsible for

managing one or more activities.3. Determine reasons used for closeness ratings andrecord on the relationship chart.

4. Assign a closeness rating to each pair-wisecombination of activities and record the code for the

reason behind the rating.5. Review the relationship chart with those providing

input to the ratings and make appropriateadjustments in the ratings.



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Activity Relationship Analysis

Activity relationships are often translated intoproximity requirements (yakinlik talepleri) Activities with strong, positive relationships are located close

together

Activities with strong, negative relationships are separated

Proximity relationships can sometimes be satisfiedwithout physical separation Activities with high information exchange can be linked with

communication systems Negative relationships can be satisfied by enclosing noisy

areas, venting fumes, etc., as opposed to physical separation


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Activity relationship chart constructionprocess is complicated by the multiple typesof relationships that exist and influence thelayout.

It may be necessary to determine the majortypes of relationships and create a separaterelationship chart for each one.For example, a relationship chart might be created

for each of material flow, personnel flow, andequipment flow.

Activity Relationship Analysis

Space Design


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Calculation

Method

Minimum Op. Space = 60cm X 90cm

Allowance For Between-Department Aisles

ERH

SQN=

RouteSheets

ProductionQuantities

Machine space including travel (MSPACE)

Operator and maintenance space (OMSPACE)

WSPACE = MSPACE + OMSPACE + STSPACE

TOTAL WORKSTATION SPACE

DEPARTMENTAL SPACE

+

+

Storage space (STSPACE)

Input buffer storageSupplies & maintenance materialsTools, dies, fixturesRework, scrap, wasteOutput buffer storage

TRANSPORTATION SPACE

AislesFloor level conveyors

Space Design

Yer(Mekan-Alan) Tasarm


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Hesaplama

Metodu

Minimum Operator Alan = 60cm X 90cm

Departman Aralar iin Gerekli Boluk Alan

ERH

SQN=

Dolanmemas

retimMiktarlar

Makine yeri ve dolama yeri (MYER)

Operatr ve Bakm (OBYER)

YER= MYER +OBYER+DYER

TOPLAM STASYON YER

DEPARTMAN ALANI

+

+

Depo Yeri (DYER)

Girdi Tampon Depo AlanGereler ve Bakm MalzemeleriAralar ve DemirbalarIskarta, atk, ve yeniden allacaklarkt Tampon Alan

TAIMA YER

Koridorlar

Tama Bantlar

Yer(Mekan-Alan) Tasarm

chapter 3-6 fsa

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