Famformjslean

PFAST: Software for Part Family Formation and Production Flow Analysis for Implementing JobshopLean (JSLEAN) Manufacturing
in Custom Forge Shops

Shahrukh A. Irani and Heng Huang Department of Industrial, Welding and Systems Engineering The Ohio State University Columbus, OH 43210
Role of Facility Layout in Lean Manufacturing

Lean Manufacturing is a manufacturing philosophy that shortens the lead time between the receipt of a customer order and the shipment of that order to the customer by eliminating waste. Anytime that an order is delayed, the cost of one or more of the Seven Types of Wastes overproduction, queuing, transportation (or material handling) time, inventory (raw material, WIP and finished goods), unnecessary motions and travel by operators to perform non-standardized work, defective (or reworked) products and underutilized workforce skills gets added to the cost of producing the order and prevents on-time delivery of the order to the customer. Empirical evidence indicates that, in any manufacturing facility, typically 95% of the production lead time of an order is comprised of only two of the Seven Types of Wastes Queuing at each workcenter and Transportation between workcenters which significantly reduce the velocity of material flows and increase WIP in a facility. These dominant wastes are the result of an incorrect and inefficient facility layout.
PFAST (Production Flow Analysis and Simplification Toolkit)1 is a software package that has automated the manual methods of Production Flow Analysis (PFA). PFAST has been used successfully to design flexible facility layouts that provide a strong foundation for implementing Lean Manufacturing in machining, pipe fabrication, forging, woodworking, cable manufacturing, electronic assembly and welding jobshops. Production Flow Analysis (PFA) is implemented in four stages to design a facility layout Factory Flow Analysis (FFA), Group Analysis (GA), Line Analysis (LA) and Tooling Analysis (TA). Each stage in PFA seeks to eliminate delays in production flows and operational wastes in a progressively smaller area of the facility. In Factory Flow Analysis (FFA) (Figure 1), the flows between shops (or buildings) on the factory site are evaluated to eliminate wastes due to transportation, communication delays, use of large containers to store WIP and use of bulk-handling material handling equipment to move the large containers over large distances. In Group Analysis (GA) (Figure 2), the flows between machines in each shop within the factory are evaluated to implement manufacturing cells to produce families of parts with identical (or similar) routings. In Line Analysis (LA) (Figure 3), the flows between machines in each cell are evaluated. A layout for the cell is designed for efficient inter-machine material handling, multi-machine tending by individual operators and minimum wasted motions by operators. In Tooling Analysis (TA) (Table 1), the flows at each machine in a cell are evaluated to optimize the workstation layout for ease of machine operation and rapid execution of setup activities, such as machine loading/unloading, tool changes, fixture changes, parts inspection and cleanup.
Hybrid Cellular Layouts for Jobshops

Like all other jobshops, custom forge shops that pursue military/government contracts from the DLA (Defense Logistics Agency) and DOD (Department Of Defense), are complex high-variety low-volume manufacturing facilities where the changes in product mix, volume, customer base, workforce skills, process technology, etc. are significant. A complete reorganization of a typical jobshop into a Cellular Layout may be ill-advised due to the inherent inflexibility of manufacturing cells. Cells cannot adapt to changes in product mix, demand volumes, capacity requirements and production schedules. Therefore, unlike the traditional manufacturing cells in a Cellular Layout, Hybrid Cellular Layouts provide an effective foundation for jobshops to configure their facility layouts for flexibility plus waste-free material flow. These layouts integrate the flexibility of a Process Layout with the manufacturing focus of a Cellular Layout to achieve waste-free and high-velocity flows of orders in any Make-To-Order (MTO) facility.
Further Reading
Interested individuals can obtain a copy of the book Hybrid Cellular Layouts: New Ideas for Design of Flexible and Lean Layouts for Jobshops by contacting the first author2.
1
Software for Design of Hyrbid Cellular Layouts
For further information on PFAST, please visit http://www-iwse.eng.ohiostate.edu/ISEFaculty/home.html and click on Irani, Shahrukh to access the literature under Research: Future Manufacturing and Production Facilities. 2 Email: [email protected] Phone: (614) 688-4685
M A T E R IA L
28 15 27 1 1 126 84 1 3 3 2 5 1 27 45 1 151 8 1 12 26 D 1 2 3 4 5 6 9 EPARTM ENTS = BLANKS = SHEET M ETAL W O RK = FO RG E = W E L D IN G D E P T = M A C H IN E S H O P = AS SE M B LY = O U T S ID E F IR M S 3 24 3 1 4 16 2 1 3 1
53
F IN IS H E D PRODUCT
M A T E R IA L S
M A T E R IA L S
3 & 4
F IN IS H E D PRODUCT
F IN IS H E D PRO DUCT
Figure 1 Factory Flow Analysis

(Source: Burbidge, J. L.1971, April/May. Production Flow Analysis. The Production Engineer, 139-152)
K 4 8 2 5 1 A M A C H I N E / W O R K S T A T I O N DMT(3) DM(3) PG DXY(3) P&GR PGR PGH PGG P&G RP PGB W&P WG3
L 4 8 3 8 8
L 4 8 2 6 7 B
M 4 4 2 7 6 E
M 4 7 6 9 3 F
L 4 8 3 8 8 M
M 4 8 1 9 5 C
M 4 4 2 7 6 D
E 4 1 7 9 5
E 4 8 5 9 6
E 3 4 2 6 7
PART/PRODUCT E E K E E 1 1 4 4 4 2 2 7 7 8 2 2 6 7 5 0 8 9 8 8 4 8 7 2 6
K 3 4 5 9 6
E 3 3 4 9 4
M 4 8 2 6 5 D
K 4 4 2 7 6 C
M 4 5 6 9 1 D
M 4 5 6 9 1 B
M 4 8 3 8 6 H
K 3 4 0 9 8 A X X
E 7 3 9 2
E 4 6 3 6 4
E 3 3 2 9 5
K 4 5 1 9 9
K 4 3 5 9 0
M 6 1 5 9 2
E 1 8 6 9 4
X X X X X X X X
X X
X X
X X X X X X X X X
X X
X X X
X X X
X X X
X X
X X X X X X X X X X X X X X
X X X X X X
X X X
COMPONENT MACHINE CHART. INITIAL RECORD. FORGE. PART/PRODUCT M M E E E 4 4 3 1 1 8 4 4 2 8 1 2 2 2 6 9 7 6 0 9 5 6 7 4 4 C D
L 4 8 2 6 7 B PG DM 3/1 DXY 3/1 RP P&G DMT 3/2 DM 3/2 DXY 3/2 W&P WG3 PGG PGB PGR DMT 3/3 DM 3/3 P&GR X X X
K 3 4 5 9 6
M 4 8 2 6 5 D X X
E 3 3 4 9 4
K 4 4 2 7 6 C X
L 4 8 3 8 8 M X
E 7 3 9 2
K 3 4 0 9 8 A
K 4 5 1 9 9
K 4 3 5 9 0
M 6 1 5 9 2
E 4 1 7 9 5
E 4 8 5 9 6
M 4 8 3 8 6 H
K 4 8 2 5 1 A
L 4 8 3 8 8
M 4 5 6 9 1 D
M 4 5 6 9 1 B
M 4 4 2 7 6 E
K 4 7 6 9 7
E 4 7 7 8 2
E 4 6 3 6 4
E 1 2 2 8 8
E 3 3 2 9 5
E 4 8 5 8 6
M 4 7 6 9 3 F
M A C H I N E / W O R K S T A T I O N
X FAMILY - 1
GROUP-1
X X X
X X
X X FAMILY - 2
GROUP-2
X X X X X
X X X X X
X X X X X
X X X
X X
X X
X X
X X
X X X X X
ONE EXCEPTION
X X
X X
X X X X
FAMILY 3 COMPONENT MACHINE CHART. AFTER FINDING FAMILIES AND GROUPS
Figure 2 Group Analysis

(Source: Burbidge, J. L.1971, April/May. Production Flow Analysis. The Production Engineer, 139-152)
GROUP-3
X X
X X
X X
M A T E R IA L
65 1 HS4 2
1 3 M O 1 2
7 2 HS
11
5 M V
7 D H
6 M H
4 DS
8 SA 41 2 5 4 4 16 2
G R O U P F L O W N E T W O R K D IA G R A M - G R O U P 2
M A T E R IA L S
72 1 HS4 17 42 15 8 SA 72 S IM P L IF IE D G R O U P F L O W N E T W O R K - G R O U P 2 4 DH 8 5 6 2 6 M H 4 1 1 7 D S 3 1 2 5 M V
Figure 3 Line Analysis (Source: Burbidge, J. L.1971, April/May. Production Flow Analysis. The Production Engineer, 139-152) Table 1 Tooling Analysis (Source: Gallagher, C. C. & Knight, W. A. (1973), Group Technology, London, UK: Butterworths)
Digit 1 Method of holding 3 Jaw 0 chuck outer 3 Jaw 1 chuck inner 42 160 Digit 2 Dimension 3 Jaw chuck Bore Dw Ove dia. rall < 40 41 100 101 200 301 400 401 500 501 1000 Digit 3 Digit 4 Special attachment s w/o Digit 5 Matching with Boring tool carrier w/o Boring, countersinking, reaming, tapping. Only outer turning. Digit 6 Digit 7 Digit 8 Surface accurac y rough turned fine turned
L L/Dw<0. 1 L/Dw<0. 5
Quadruple single point tool holder w/o
Material
GGformed STformed
Axial copying
Uniform cutting, w/o accuracy. Uniform cut, or staggered cut, with accuracy, simple boring up to 48 . Outer shaping, chamfering, inserting with form tool, not copying. 3 with 4 Shaping, inserting chamfering with form tool; copying.
4 Jaw 2 chuck
60
250
L/Dw up to limit of chuck
Face copying
NEformed
outer fit
Spring collet
80
315
Shafts< 500 Shafts 500 1000 Shafts 1m2m
2 Axis copying Conical Surface tapering 1 2 Steep cone
1 with 2 Shaping, etc. with form tool; with 3; not copying. Inner shaping inserting chamfering; with 3; copying.
GG-cut off
inner fit (+ outer) position al accurac y polishin g
Mandre 4 l or arbor Jig or 5 fixture
80
400
ST-cut off
125
500
NE-cut off
Betwee 6 n centers 7 8 Chuckcenter
> 1000
Shafts 2m5m Shafts > 5m
Steadie s Eccentr 9 ic (face plate)
Short thread milling Threading with lead screw Thread with copying Unround copying
Inner & outer at the same time
5 with 2 & 1 or 3 6 with back tool holder
GG-bar ST-bar NE-bar
knurling , etc.
6 7 8 9
Automatic cycle with 4th & 5th digits
nonmetal

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PFAST: Software for Part Family Formation and Production Flow Analysis for Implementing JobshopLean (JSLEAN) Manufacturing

in Custom Forge Shops

Role of Facility Layout in Lean Manufacturing

Hybrid Cellular Layouts for Jobshops

Software for Design of Hyrbid Cellular Layouts

28 15 27 1 1 126 84 1 3 3 2 5 1 27 45 1 151 8 1 12 26 D 1 2 3 4 5 6 9 EPARTM ENTS = BLANKS = SHEET M ETAL W O RK = FO RG E = W E L D IN G D E P T = M A C H IN E S H O P = AS SE M B LY = O U T S ID E F IR M S 3 24 3 1 4 16 2 1 3 1

Figure 1 Factory Flow Analysis

COMPONENT MACHINE CHART. INITIAL RECORD. FORGE. PART/PRODUCT M M E E E 4 4 3 1 1 8 4 4 2 8 1 2 2 2 6 9 7 6 0 9 5 6 7 4 4 C D

FAMILY 3 COMPONENT MACHINE CHART. AFTER FINDING FAMILIES AND GROUPS

Figure 2 Group Analysis

Quadruple single point tool holder w/o

L/Dw up to limit of chuck

Shafts< 500 Shafts 500 1000 Shafts 1m2m

2 Axis copying Conical Surface tapering 1 2 Steep cone

inner fit (+ outer) position al accurac y polishin g

Mandre 4 l or arbor Jig or 5 fixture

Betwee 6 n centers 7 8 Chuckcenter

Shafts 2m5m Shafts > 5m

Steadie s Eccentr 9 ic (face plate)

Inner & outer at the same time

5 with 2 & 1 or 3 6 with back tool holder

GG-bar ST-bar NE-bar

Automatic cycle with 4th & 5th digits

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