Facilities Planning and Warehouse Operations

INDU 6251 – Fall 2023

Product Process and Schedule Design

Makbule Kandakoglu, PhD

05 September, 2023

Some of the slides are adapted from the course textbook and the lecture notes provided by Prof. Andrea Schiffauerova and Prof. Ali Akgunduz
Outline
• Product Design
• Process Design

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Facilities Planning Process
1. Define the products to be manufactured and/or assembled.
2. Specify the required manufacturing and/or assembly processes and related
activities.
3. Determine the interrelationships among all activities.
4. Determine the space requirements for all activities.
5. Generate alternative facilities plans.
6. Evaluate the alternative facilities plans.
7. Select the preferred facilities plan.
8. Implement the facilities plan.
9. Maintain and adapt the facilities plan.
10. Update the products to be manufactured and/or assembled and redefine the
objective of the facility.

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Product, Process and Schedule Design
• Before we start developing alternative facility plans, we have to find answers
for the following questions

Answers for the first 5 questions

1. What is to be produced can be obtained from:
2. How are the products to be produced • Product design
• Process design
3. When are the products to be produced
• Schedule design
4. What quantity of each product to be produced
5. How long the product to be produced
Answer for the last question might
be searched outside of the
6. Where are the products to be produced company.
Here, the supply chain concepts
becomes the determinant factor

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Product, Process and Schedule Design
Answering these questions will help to develop the first part of your term projects!

• Product design
• Market analysis
• Vendors selection
• Equipment and personnel requirements
• Location selection
• Plant layouts designs (using CAD) and selection of the best
• Issues in supply chain management
• Materials handling
• Simulation/optimization studies
• Life cycle analysis of both product and facility
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Product, Process and Schedule Design
• Where are the products to be produced?
• Answering this sixth question has become much more complicated in today’s
environment

• Global sourcing effect

• Today countries are closer-than-ever
• Companies are working together

Examples:
• Cars are assembled with parts that are manufactured by several different companies
in several different countries
• Many food products might be imported from outside and packed in Canada (Beer,
jelly, frozen vegetables etc.)
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Product, Process and Schedule Design
• Product design
• Product designers determine:
• Product specifications (dimensions, material, packaging, etc.)
• Process design
• Process designers determine:
• How the product will be produced
• Schedule design
• Production planners determine:
• Production quantities
• The schedules for the equipment

• Where does the facility planner come in?

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Product, Process and Schedule Design

• Facility planner is dependent on timely and accurate input from product, process
and schedule designers
• These groups work together to create profitable efficient facilities
• The need for close coordination among the four groups

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Product Design
• Determination of a product to be produced
• Detailed design of the product

Product Design – Product Determination

• Based on input from:
• Marketing
• Manufacturing
• Finance
• etc.
• In most cases, the final decisions are made by the top management

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Product Design – Product Determination
• The design of a product is influenced by aesthetics, function, materials, and
manufacturing considerations.
• Marketing, purchasing, industrial engineering, manufacturing engineering,
product engineering, and quality control, among other factors, will influence
the design of the product.
• In the final analysis, the product must meet the needs of the customer.

• This challenge can be accomplished through the use of Quality Function

Deployment (QFD) and Benchmarking.

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Product Design – Product Determination
• QFD is an organized planning approach to identify
customer needs and to translate the needs to product
characteristics, process design, and production
requirements.

• Benchmarking is used to identify what the competition is

doing to satisfy the needs of customers or to exceed
customer expectations.
• It can also be used to identify best practices from the most
successful organizations.

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Product Design – Detailed Design
• Finally, detailed designs take place
• CAD designs
• Prototypes
• Assembly designs
• 2D drawings and dimension determinations

• All these can be observed easily in most of the commercial CAD programs.

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Product Design – Detailed Design
• Concurrent Engineering is a systematic way of enabling communication
between all related units during the product development

• The aim is to minimize the changes in design parameters once the design is
finalized
• Most of the manufacturing cost is set during the design phase
• Changing the design later in the process costs significantly

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Product Design – Detailed Design
• Once the product design is completed, usually following documents are
provided for the facilities planning process as inputs
• Exploded assembly drawings
• Exploded parts photographs
• Component part drawings

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Exploded Assembly Drawings – An Example

Source: Facilities Planning, 4th edition, Tompkins et al., 2010

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Exploded Parts Photographs – An Example

Source: Facilities Planning, 4th edition, Tompkins et al., 2010

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Component Part Drawings – An Example

Source: Facilities Planning, 4th edition, Tompkins et al., 2010

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Component Part Drawings – An Example

Source: Facilities Planning, 4th edition, Tompkins et al., 2010

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Product, Process and Schedule Design

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Process Design
• Determination of how the product is to be produced
• Who should do the processing? (Which part of the products should be
made?)
• How the part will be produced?
• Which equipment will be used? (for the parts which will be made in-house)
• How long will it take to perform the operation?

• Production methods are the most fundamental factor affecting the physical
layout

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Process Design
Within the process design process, we need to consider following issues
1. Process identification
• Make-or-buy analysis
• Parts identification

2. Process selection
• How the product will be made (operations, equipment, raw material, etc.)

3. Process sequencing
• How components are put together

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Process Design – 1. Process identification
Make-or-buy decisions
• The scope of the facility depends on the level of vertical integration
• How are the make-or-buy decisions made?
• Can the item be purchased?
• Should we go for subcontracting?
• Supplier
• Contractor
• Can we make the item?
• Is it cheaper for us to make than to buy?
• Is the capital available so that we can make it?

• Managerial decisions requiring input from finance, industrial engineering, marketing, process
engineering, purchasing, human resources, etc.

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Process Design – 1. Process identification

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Process Design – 1. Process identification
The input to the facility planner is a listing of the items to be made/purchased.
• Parts list –component parts of a product:
• part numbers
• part name
• number of parts per product
• drawing references
• Bill of materials – structured parts list:
• contains hierarchy referring to the level of product assembly

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Part List – An Example

Source: Facilities Planning, 4th edition, Tompkins et al., 2010

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Bill of Materials (BOM) – An Example

Source: Facilities Planning, 4th edition, Tompkins et al., 2010

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Process Design – 2. Process Selection
• How the products will be made

• 6-step procedure:
1. Define elementary operations
2. Identify alternative processes for each operation
3. Analyze alternative processes
4. Standardize processes
5. Evaluate alternative processes
6. Select processes

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Process Design – 2. Process Selection
• Route sheet
• output of process selection, it identifies processes, equipment and raw
materials

Data Production Example

Component name and number Plunger housing – 3254
Operation description and number Shape, drill, and cut off – 0104
Equipment requirements Automatic screw machine and
appropriate tooling
Unit times (Per components) Set-up time: 5 hrs.
Operating time: 0.0057 hrs
Raw material requirement 1 in. diameter X 12 ft aluminum bar
per 80 components

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Process Design – 2. Process Selection

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Process Design – 3. Process Sequencing
• The method of assembling the product
• Assembly chart – shows how the components are combined
• Operation process chart – gives an overview of the flow within the facility
• A combination of route sheets and assembly charts
• Precedence diagram – establishes precedence relationships

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Assembly Chart This was identified in
route sheet already

Assemblies

Inspection

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Operation Process Chart
• Route sheets provide
information on production
methods
• Assembly charts includes how
components are put together

• Combination of route-sheets and

assembly-charts (Operation
Process Chart) gives an
overview of the flow within the
facility

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Precedence Diagrams
• In the operation process charts, it is
not clear if two machining operations
have and dependency to each other

Observe the part#3254

• Operations 0204 and 0304 can be
done at the same time
• Yet, the operation 0104 should be
completed before both 0204 and 0304

• We cannot observe this information in

operation process charts

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Next Lecture

• Schedule and facility design

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