IE 4355 Facilities Planning - Lecture 1

Introduction

• Course Title: IE 4355 Facilities Planning
• Lecture Title: Product Process and Schedule Design

Course Objectives

1. Understand principles of facilities location, layout, and material handling systems.
2. Learn formulations, models, and procedures for facilities layout planning.
3. Learn fundamental principles of material handling.
4. Design layouts incorporating product process and personnel requirements.

Lecture Focus

• Focus on product, process, and schedule design, particularly facilities design.

Key Topics Covered

1. Product Design

   • Deciding which products to be produced.
   • Influenced by aesthetics, function, materials, and manufacturing considerations.
   • Important influences include marketing, purchasing, engineering, quality control.
   • Use of pictorial representations and prototypes.
   • Decisions on manufacturing parts in-house or purchasing.
   • Use of CAD for detailed component drawings.
   • Concurrent engineering to improve function-cost relationship and speed to market.

2. Process Design

   • Decision on purchasing or producing parts in-house.
   • Process designers determine production methods, equipment, and operation times.
   • Input from finance, engineering, marketing, HR among others.
   • Flow charts and decision diagrams assist in decision-making.
   • Use of part lists and bills of materials.
   • Process selection procedure (defining operations, analyzing alternatives, standardizing processes).
   • Outputs include processes, equipment, raw materials required.
   • Route sheets for production planning.

3. Assembly and Operations Charts

   • Assembly charts show product assembly methods starting from final product.
   • Operation process charts incorporate route sheets and assembly charts.
   • Precedence diagrams outline operation sequences.

4. Schedule Design

   • Deciding production quantity (lot size) and schedule.
   • Involves production requirements, machine requirements, and operation requirements.
   • Calculating production requirements accounting for defective rates.
   • Example provided for calculating production requirements.

Important Concepts

• Concurrent Engineering: Simultaneous consideration of multiple design factors.
• CAD Systems: Used for detailed product design and visualization.
• Route Sheets: Document detailing component operations and requirements.
• Assembly Charts: Visualize assembly from final product to components.
• Operation Process Charts: Include both assembly and process details.
• Production Scheduling: Planning lot sizes and timing based on demand forecasts.
• Defective Rate Calculations: Determine start quantities required to meet desired outputs.