Facilities Planning (ID: 8054212-3)

4- Product, Process and Schedule Design (Part 1)

The Week of 13/02/2022

Dr. Hussain Abualkhair
College of Engineering – Industrial Engineering Program
 Facilities Planning Hierarchy

Facility Systems
Design
Facilities
Location
(Macro)
Facilities Layout
Planning Design
Facilities
Design
(Micro) Handling
Systems
Design

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 Introduction
▪ The facilities planning process for manufacturing can be listed as:

1. Define the products to be manufactured.

2. Specify the manufacturing processes and related activities required to produce the products.
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 redefine the objective of the facility.

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 Introduction

▪ What questions should be answered before developing alternative

facility designs?
• 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?

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 Data for Strategic Facility Design – Example

1. What is to be produced?
→ 1/16 scale models of new and old tractors.
2. How the products are to be produced?
→ Die/sand casting, trimming/drilling, painting, assembling, direct shipping.
3. When the products are to be produced?
→ Within 1/2 month prior to introduction, and 2 months after order.
4. How much of each product will be produced?
→ Batch production runs of 100 to 1000, ~ 8 new & 20 total models/yr.
5. For how long will the products be produced?
→ 2 – 3 yrs/model, product lifecycle of 15 – 30 yrs, facility life >50 yrs
6. Where the products are to be produced?
→ Small, rural Iowa town.

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 How are facility designs created?
▪ Many companies are using cross-functional teams to facilitate the facility plan.
▪ Many organizations have created teams with product, process, scheduling, and
facilities design planners and with personnel from marketing, purchasing, and
accounting to address the design process in an integrated, simultaneous, or
concurrent way. Customer and supplier representatives are also involved in this
process.
▪ These teams are often referred to as concurrent or simultaneous engineering teams
and are reducing the design cycle time, improving the design process, and eliminating
engineering changes.

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 What have been the results of companies
using cross-functional teams?

▪ Companies implementing this integrated approach have

reported impressive results in cost, quality, productivity,
sales, customer satisfaction, delivery time, amount of
inventories, space and handling requirements, and building
size, among others

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 Why do we need to use cross-functional
teams?
▪ The facility design will impact everyone in the business. To create buy-
in* from everyone in the facility, representatives from all areas should
have input in the design.
▪ Product, process, schedule, and facilities design decisions must be
made together.

*buy-in signifies the commitment of interested or affected parties to a decision

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Relationship between Product (PD), Process (PC) &
Schedule (SC) Design and Facilities Design (FD)

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 Product Design
Product designers specify what the end product is to be in terms of
dimensions, material composition, and perhaps, packaging.

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 Product Design

▪ What is involved in product design?

• Product design involves both the determination of which products are
to be produced and the detailed design of individual products.
• Decisions regarding the products to be produced are generally made
by top management based on input from marketing, manufacturing,
and finance concerning projected economic performance.

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 What product factors must we keep in
mind when designing a facility?

▪ How often will the product change? Often or very little?

How will this impact the design of the facility?
• If the product is likely to change often, then a very flexible facility
design is needed.
• If the product is not likely to change, then the facility design can
be optimized to facilitate the manufacture of the product.

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 What information do we need about the
product?
1- Detailed operational specifications
2- Pictorial representations
3- Prototypes of the product
▪ Exploded assembly drawings are quite useful in designing the layout and handling
system.
▪ Photographs and drawings (Exploded Parts Photograph) allow the planner to visualize
how the product is assembled, provide a reference for part numbers, and promote
clearer communications during oral presentations.
▪ Detailed component part drawings are needed for each component part.

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 Exploded Assembly drawings
Exploded assembly
drawings are quite useful in
designing the layout and
handling system.

These drawings generally

omit specifications and
dimensions, although they are
drawn to scale.

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 Exploded Photograph
▪ Exploded photograph can be used to show the parts properly oriented. Photographs and drawings
allow the planner to visualize how the product is assembled, provide a reference for part
numbers, and promote clearer communications during oral presentations.

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 Detailed Component Part Drawings
▪ Detailed component part drawings provide part specifications and dimensions in sufficient detail to allow part fabrication.
▪ The combination of exploded assembly
drawings and component part drawings
fully documents the design of the products.

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 Process Design
▪ What is process
design?
• The process
designer or
process planner is
responsible for
determining how
the product is to
be produced.

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 Tools
▪ A partial list (dependent on product and service):
• Process Flowcharts and Process Maps
• Make vs. Buy
• Parts Lists
• Bill of Materials
• Route Sheets
• Assembly Charts
• Operations Process Charts
• Precedence Diagrams

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 Process Flowchart
UPS

Active Parcel
Receiving Picking Packing Shipping
Bins Post

Reserve Mono- Next-Day

Storage gramming UPS

Embroid-
Quality
ering
Assurance
Back to
Vendor

Hemming

Gift
Boxing

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 Process Maps

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 What is Involved in Process Design?

• The process planner addresses:

o 1. Who should do the processing; namely, should a particular product,
subassembly, or part be produced in-house or subcontracted to an
outside supplier or contractor? The "make- or-buy" decision is part of
the process planning function.
o 2. How the part will be produced, which equipment will be used, and
how long it will take to perform the operation.

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 Make / Buy Decision

▪ Who should do the processing? BUY

No

Yes Can we Is it cheaper

Can item be Yes Yes Is the capital
make the for us to
purchased? available?
item? make?

No No No Yes

MAKE BUY BUY MAKE

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 Parts List

PARTS LIST
Company: TW Inc. Prepared By: JSU
1. Part numbers. Product: Air Flow Regulator Date: 6/30/2003
2. Part name.
Part No. Name Drwg. No. Qty/unit Material Size Make/Buy
3. Number of parts per 1050 Pipe plug 4006 1 Steel 0.5" x 1.00" Buy
2200 Body 1003 1 Aluminum 2.75" x 2.5" x 1.5" Make
product 3250 Seat Ring 1005 1 Stainless Steel 2.97" x 0.87" Make
4. Drawing references 3251 O-Ring - 1 Rubber 0.75" diam. Buy
3252 Plunger 1007 1 Brass 0.812" x 0.715" Make
3253 Spring - 1 Steel 1.4" x 0.225" Buy
3254 Plunger Housing 1009 1 Aluminum 1.6" x 0.225" Make
3255 O-Ring - 1 Rubber 0.925" diam. Buy
4150 Plunger Retainer 1011 1 Aluminum 0.42" x 1.2" Make
4250 Lock Nut 4007 1 Aluminum 0.21" x 1.00" Buy

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 Identifying Required Processes

▪ Why is identifying the required processes important?

• The scope of a manufacturing facility must be established by determining
the processes that are to be included within the facility.
▪ How do we identify the processes required to produce a product?
• A route sheet for each product
• Produce a matrix of products compared to processes
• This matrix may help you identify products that could be grouped into cells

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 Route Sheet
Company: ARC Inc. Part: Plunger Housing Prepared by: JSU
Produce: Air Flow Regulator Part No. 3254 Date: 6/6/03
Oper. Operation Machine Tooling Setup Oper. Time Mtls.
No. Description Type (hr.) (hr.) Parts
0104 Shape, drill, cut Auto sc. .5 in dia coller, cir. Form 5 0.0057 Alum
off Machine tool, .45” diam center drill 1”x12’
0204 Machine Slot and Chucker 0.045” slot saw, turret slot 2.25 0.0067
thread
0304 Drill 8 holes Auto dr. unit 0.078” diam twist drill 1.25 0.0038
0404 Debur and Blow Drill press Deburring tool with pilot 0.5 0.0031
out
SA 1 Enclose Dennison None 0.25 0.0100
subassembly hydraulic press

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 Identifying Required Processes
▪ What is the scoop of a facility that does everything from purchase the raw materials
to produce a final product?
▪ What is the scoop of a facility that purchases components and assembles finished
products?
▪ Why would a bill of materials be helpful in designing a facility?
• A bill of materials lists all the parts required to produce a product. This it details the product
drawing number and the quantities of the required parts.
• This information will help you determine the storage requirements at each station and the
size of the receiving area.

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 Bill of Materials
BILL OF MATERIALS
Company: TW Inc. Prepared By: JSU
Product: Air Flow Regulator Date: 6/30/2003

Level Part No. Name Drwg. No. Qty/unit Make/Buy

0 0021 Air Flow Regulator 0999 1 Make
1 1050 Pipe plug 4006 1 Buy
1 6023 Main assembly - 1 Make
2 4250 Lock Nut 4007 1 Buy
2 6022 Body Assembly - 1 Make
3 2200 Body 1003 1 Make
3 6021 Plunger Assembly - 1 Make
4 3250 Seat ring 1005 1 Make
4 3251 O-Ring - 1 Buy
4 3252 Plunger 1007 1 Make
4 3253 Spring - 1 Buy
4 3254 Plunger Housing 1009 1 Make
4 3255 O-ring - 1 Buy
4 4150 Plunger retainer 1011 1 Make

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Example BOM: Air Flow Regulator

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 Selecting the Required Processes
▪ Steps in Process Selection
1. Define elemental operations
2. Identify alternative process(es) for each operation
3. Analyze alternative processes for each operation
4. Standardize processes for each operation
5. Evaluate alternative processes for overall production
6. Select processes for overall production

The outputs from the process selection procedure are the processes, equipment, and raw materials required for the in-house
production.
Output is generally given in the form of a route sheet.

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 Operation Process Chart
▪ The operation process chart can also include materials needed for the fabricated
components.
▪ Additionally, operation times can be included in this chart and placed to the left of
operations and inspections.
▪ A summary of the number of operations and inspections and operation times can be
provided below the chart.
▪ The operation process chart can be complemented with transportations, storages,
and delays (including distances and times) when the information is available.

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