FACULTY OF MECHANICAL ENGINEERING

LAYOUT DESIGN - Part 1

UNIVERSITI TEKNOLOGI MALAYSIA

PRODUCT, PROCESS AND SCHEDULE

Among the questions to be answered before facility

planning can be done

What is to be produced ?
How are the products to be produced ?
When are the products to be produced ?
How much of each product will be produced ?
For how long will the products be produced ?
Where are the products to be produced ?

The answers can be obtained from product design,

process design, and schedule design
Product design, process design and schedule design
must be done concurrently with facilities design
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PRODUCT DESIGN

Product design involves the determination of which

products to be produced and the detailed design of
individual products
DIFFERENT PRODUCT DIFFERENT FACILITY
Basic product design data can be obtained from
production drawings, prototypes of the product, etc

PRODUCT DESIGN assembly drawing

Product

PROCESS DESIGN

Process design decisions determine whether

a part will be purchased or produced,
Selection of process
Sequence of process
This information can be obtained from parts list, bill of
materials, route sheet, assembly chart, precedence
diagram

PROCESS DESIGN make or buy

Options buy raw materials and do in house fabrication

and assembly, or buy component and only do in house
assembly
Scope and magnitude of activities are dependent on
level of vertical integration

PROCESS DESIGN make or buy

PROCESS DESIGN make or buy

- part lists

The input to the facilities planner is a listing of the

items to be made and the items to be purchased.
The listing often takes the form of a parts list or a bill
of materials
The parts list provides a listing of the component parts
o f a product. In addition, a parts list includes at least
the following
Part number
Part name
Number of parts per product
Drawing references
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PROCESS DESIGN make or buy

- parts list

parts lists

PROCESS DESIGN make or buy

- bill of materials

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PROCESS DESIGN make or buy

- bill of materials

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PROCESS DESIGN selection of process

Product identification process selection (include

CAPP) Route sheet

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PROCESS DESIGN selection of process

route sheet

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PROCESS DESIGN sequence of process

Assembly chart
Operation process chart
Precedence diagram

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PROCESS DESIGN sequence of process

assembly chart

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PROCESS DESIGN sequence of process

operation process chart

purchased or produced (make or buy)

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PROCESS DESIGN sequence of process

precedence diagram

purchased or produced (make or buy)

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SCHEDULE DESIGN

Schedule design decisions provide answers to the

questions
How much to produce (volume)
When to produce
Associated with these decisions is the determination of
the number of machines, number of shifts, number of
employees, space requirements, storage requirements,
material handling equipment, building size etc.
Consequently, plant layout will be very much affected
Information obtained from Master Production
Schedule (MPS)
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SCHEDULE DESIGN volume-variety

Volume-variety chart (paretos law)

Mass production area for 15% of high-volume
items and a job shop arrangement for the remaining
85% of the product mix
Very important in determining the layout type

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SCHEDULE DESIGN scrap estimates

The market estimate specifies the annual volume to be

produced for each product
To produce the required amount of product, the
number of units scheduled through production must
equal the market estimate plus a scrap estimate.
Ik =
Ok
1 Pk

I1 =

On
(1-P1)(1-P2)(1-Pn)
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SCHEDULE DESIGN scrap estimates

A product has a market estimate of 97,000 components

and requires three processing steps (turning, milling
and drilling) having scrap estimates of P 1 = 0.04, P2 =
0.01 and P3 = 0.03
Input for drilling, I3 =
97,000 = 100,000
1 0.03
Input for milling, I2 = 100,000 = 101,000
1 0.01
Input for turning, I1 = 101,000 = 105,219
1 0.04
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SCHEDULE DESIGN scrap estimates

Scrap estimates
I1 =
97,000
(1 0.03) (1 0.01) (1 0.04)
= 105,219

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SCHEDULE DESIGN - Machine Assignment

The combination of product, process and schedule

design decisions influences the number of employees
involved in producing the product
Decisions regarding the assignment of machine to
operators can affect the number of employees
Assumptions
Semiautomatic production equipment
Machines are identical
Times required to load and unload each machine are
constant
Automatic machining time is constant
Time for operator to travel between machines is 23

SCHEDULE DESIGN - Machine Assignment

Multiple activity chart shows the activities of one or

more people and one or more machines

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SCHEDULE DESIGN - Machine Assignment multi activity chart

Machine Assignment
The

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SCHEDULE DESIGN - Machine Assignment

0.5 minute to travel between machines

1.0 minute to load a machine
1.0 minute to unload a machine
6 minutes of automatic machine time
0.5 minute to inspect and pack a finished part
operator loads M-1, walks to M-2, loads M-2, walks to
M-3, loads M-3, walks to M-1, unload M-1, load M-1,
inspects and packs the part removed from M-1, travel
to M-2 and so forth
12 minutes to achieve a steady-state condition,
thereafter a repeating cycle of 9 minutes in duration
occurs

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SCHEDULE DESIGN - Machine Assignment assignment of three machines to one operator

Machine Assignment
The

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SCHEDULE DESIGN - Machine Assignment

Let

a = concurrent activity time (eg loading / unloading )

b = independent operator activity time (walking / inspecting )
t = independent machine activity time (eg automatic machine
time)
n = ideal number of identical machines assigned an operator
m = number of identical machines assigned an operator
Tc = repeating cycle time
Io = ideal operator time during a repeating cycle
Im = ideal time for each machine during a repeating cycle

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SCHEDULE DESIGN - Machine Assignment

Excluding idle time, each machine cycle requires a + t

minutes to complete a cycle. Likewise, the operator
devotes a + b minutes to each machine during a cycle.
Hence, an ideal assignment is
n = (a + t) / ( a + b)
From the example,
n = (2 + 6) / (2 + 1) = 2.67
Not possible to have 2.67 machines so assume 3
machines.

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SCHEDULE DESIGN - Machine Assignment

Consider what will happen if m machines are assigned

The work content for the operator will be m(a + b) ,
while a machine cycle will be (a + t) in duration
The repeating cycle will be the larger of the two and
the difference in the two will be idle time.
Tc = (a + t)
if m <= n
= m(a + b) if m > n
Im = 0
if m <= n
= Tc (a + t) if m > n
Io = Tc m(a + b) if m <= n
=0
if m > n
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SCHEDULE DESIGN - Machine Assignment

If we wish to determine the cost per unit produced by

an m machine assignment, use the following
Co = cost per operator-hour
Cm = cost per machine-hour
v= Co/Cm

TC(m) = cost per unit produced based on an

assignment of m machines per operator

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SCHEDULE DESIGN - Machine Assignment

The cost per hour of a combination of m machines and

an operator totals Co + mCm
Assuming each machine produces one unit during a
repeating cycle, the cost per unt produced during a
repeating cycle can be determined as follows;

TC(m) = (Co + mCm )(a + t)/m

= (Co + mCm )(a + b)

if m <= n
if m > n

to minimize TC(m) when m <= n, m should be made

as large as possible; to minimize TC(m) when m > n,
m should be made as small as possible.
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SCHEDULE DESIGN - Machine Assignment

To facilitate the determination, let

F = TC(n) / TC(n + 1)

(Co + nCm )(a + t)

n[ Co + (n + 1) Cm ] ( a + b)

which reduces to

F=

v+ n
x n
v+n+1
n

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SCHEDULE DESIGN - Machine Assignment

If F < 1, then TC(n) < TC(n + 1) and n machines should

be assigned

If F > 1, then TC(n + 1) < TC(n) and n + 1 machines

should be assigned

If F = 1, then either n or n + 1 machines should be

assigned.

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FACULTY OF MECHANICAL ENGINEERING

THE END

UNIVERSITI TEKNOLOGI MALAYSIA

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