Facility Planning

Facility Planning How is a manufacturing facility planned?

Manufacturing Facilities • What are the major tasks in organizing a manufacturing facility? • What is the role of a manufacturing engineer? • What is an operations process chart? • What is a flow process chart?

Group Activity You have been hired by ABC company as a manufacturing engineer. Your jobs is to decide how to efficiently manufacture your class project. You have 5 minutes to discuss the product and think about how to produce it. Remember to incorporate your jigs and fixtures. Prepare a brief 2-3 minutes presentation for the class.

Manufacturing Facilities • Manufacturing takes place in a manufacturing facility. • Manufacturing Engineers design and develop manufacturing facilities. They have 5 major tasks: • Operation Selection • Material Handling Study • Tooling Design • Plant Layout • Efficiency Studies • The GOAL is to produce the product at a competitive price. (a price similar to products like it on the market)

Task 1: Selecting and Sequencing Operations • While hiring good employees and getting the right equipment is important, they must still be employed wisely. • The engineer must select (decide which process must be done) and sequence (put them in the most efficient order). • Several forms and methods are used to do this.

Operations Sheet • What operations are used to shape the product and what processes are used? • The following items are recorded on an operations sheet: • Operation name • Machine used • Tooling needed

Flow Process and Operation Process Charts • As a product is manufactured, parts must be transferred to various placed and in some cases stored. • The order of these steps and process is an important part of the manufacturing process. • Two forms are used to place manufacturing tasks in order: • Flow Process Chart • Operation Process Chart

Show a the step-by-step process for producing a single part. Describes the task Provides a code number for each task Identifies the machines used Lists tooling needed for the task Standard symbols are used to identify each task that were developed by the American Society of Mechanical Engineers (ASME) Flow Process Chart

Example: Flow Process Chart

Divide into groups of 3-4 members. Using the worksheets given, create a flow process chart for the class project. Group Activity

Operation Process Chart • An operation process chart shows how each part is made and then show the assembly of the product. • Transportation, delay, and storage tasks are not included in the chart. • The operations process chart is used in scheduling production. It shows what parts need to be finished at what time frame. This reduces the storage needed. • JIT- “Just is time” – parts arrive just in time for assembly. This helps reduce costs.

Example: Operation Process Chart

In your groups of 3-4 members… On the back of your Flow Process Chart worksheets, create an operation process chart for the class project. Use your flow process charts to help you outline your steps. You have 10 minutes to prepare your flow charts. Prepare a 2-3 minutes presentation for the class. Group Activity

Task 2: Designing Tooling • Tooling: devices such as jigs, fixtures, patterns, and templates that help workers make products better and faster. • Tooling is designed for three purposes: • Increase production speed • Increase accuracy – less waste • Increase safety

Task 3: Preparing Plant Layout • Resource flow: moving materials and people through the facility efficiently • Things to consider in the layout: • Restroom location • Break rooms • Emergency Evacuations • The plan must include: • Where to place machines • How to move material • Where to have aisles • Where to locate utility systems (electricity, water, gas, etc.) • 2 Types of Plant Layout • Process Layout • Product Layout

Groups machines by the processes they perform. Most common in custom manufacturing and intermittent manufacturing A plant can produce a number of different products and machines can be used for a variety of tasks. Process Layout Receiving Dept. E Dept. F Dept. A Dept. G Dept. D Dept. B Dept. H Dept. C Shipping

Product Layout • Places machines according to the sequence of operations. • Used in continuous manufacturing plants • The machine needed for the most operations is placed near the storage area. The machine needed second is next and so on. • Several shapes are used for continuous process lines. Straight Circular S-Shaped Random U-Shaped

Task 4: Material Handling Systems • Material handling – moving materials and products through a facility • 2 types of material handling: • Fixed path device – • Items always travel on the same path • Assembly lines • Examples: pipes, chutes, conveyors, etc. • Variable path device • Can be steered and move in various directions • Examples: forklifts, overhead cranes, tractors, trucks, etc.- they require an operator

Task 5: Improving Manufacturing Systems • Production lines can be redesigned • Operations can be redesigned • Efficiency can be evaluated • More efficient tools or machines can be used

You have been hired by ABC company as a manufacturing engineer. Your jobs is to decide how to efficiently manufacture your class project. Look back at the task (listed above) that you did at the beginning of this unit. How has your views of a manufacturing facility changed? (write a paragraph reflection in your class notebook.) Group Activity - Reflection

Review: Manufacturing Facilities What are the major tasks in organizing a manufacturing facility? What is the role of a manufacturing engineer? What is an operations process chart? What is a flow process chart?

Facility Planning