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Methods, Standards, and Work Design11th Edition
Niebel/Freivalds
Products and Facilities
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Concurrent EngineeringDefined Concurrent engineering
– the simultaneous development of project design functions
– open and interactive communication existing among all team members for the purposes of:» reducing time to market, » decreasing cost, and » improving quality and reliability
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Design for Manufacturing and Assembly
Greatest improvements related to DFMA arise from simplification of the product by reducing the number of separate parts:
» 1. During the operation of the product, does the part move relative to all other parts already assembled?
» 2. Must the part be of a different material or be isolated from other parts already assembled?
» 3. Must the part be separate from all other parts to allow the disassembly of the product for adjustment or maintenance?
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Types of Processes
Conversion - changing iron ore into steel
Fabrication - making car bumpers from plastic
Assembly - assembling a car
Testing - computer boards - not a fundamental process
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Process Flow Structures Job shop - small batches of a large number of different
products– printing, machine shop, tool & die
Batch shop - standardized job shop, products produced in batches– clothing
Assembly Line - parts move from station to station at a controlled rate– microwaves, cars
Continuous Flow - continuous versus discrete flow – beer, paint
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IV.Continuous
Flow
III.Assembly
Line
II.Batch
I.Job
Shop
LowVolume,One of a
Kind
MultipleProducts,
LowVolume
FewMajor
Products,HigherVolume
HighVolume,
HighStandard-
ization
CommercialPrinter
French Restaurant
HeavyEquipment
Coffee Shop
AutomobileAssembly
Burger King
SugarRefinery
Flexibility (High)Unit Cost (High)
Flexibility (Low)Unit Cost (Low)
Exhibit 5.10Exhibit 5.10
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Basic Production Layout Formats
Process Layout
Product Layout
Group Technology (Cellular) Layout
Fixed-Position Layout
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Flow Through Systems
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Process-Oriented Layout
Design places departments with large flows of material or people together
Dept. areas have similar processes– e.g., All x-ray machines in same area
Used with process-focused processes Examples
– Hospitals– Machine shops
© 1995 Corel Corp.
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Process-Oriented Layout Floor Plan
OfficeOffice
Tool RoomTool Room
Drill PressesDrill Presses
Table SawsTable Saws
© 1995 Corel Corp.
© 1995 Corel Corp.
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Product-Oriented Layout
Facility organized around product Design minimizes line imbalance
– Delay between work stations Types: Fabrication line; assembly line Examples
– Auto assembly line– Brewery– Paper mfg. © 1984-1994 T/Maker Co.
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1 3
2
4
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Product-Oriented Layout Floor Plan
OfficeOffice
Belt Belt ConveyorConveyor
Operations
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Cellular Layout - Group Technology (Work Cells)
Special case of process-oriented layout Consists of different machines brought
together to make a product Group Technology Benefits:
– Better human relations – Improved operator expertise – Less in-process inventory and material handling– Faster production setup
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Work Cell Floor Plan
OfficeOffice
Tool RoomTool RoomWork CellWork Cell
SawsSaws DrillsDrills
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Fixed-Position Layout
Design is for stationary project Workers & equipment come to site Complicating factors
– Limited space at site– Changing material needs
Examples– Ship building– Highway construction
© 1995 Corel Corp.
© 1995 Corel Corp.
© 1995 Corel Corp.
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Fixed Position Layout
Question: What are our primary considerations for a fixed position layout?
Answer: Arranging materials and equipment concentrically around the production point in their order of use.