Lecture Two Part One Continuation Notes

Departmental Planning

• Involves various areas: production, support, administrative, and service.
• Production planning departments consist of workstations grouped during facilities layout process.
• Classification of production planning departments:
  1. Product Fixed
  2. Product Family (Group Technology)
  3. Process Planning

Factors for Choosing Production Planning Strategies

• Based on volume (how many products produced) and variety (types of products).
  • High Volume / Low Variety: Product Layout
  • Low Volume / High Variety: Process Layout
  • Low Volume / Low Variety: Fixed Location Layout (e.g., airplane manufacturing)
  • Medium Volume / Medium Variety: Product Family Layout

Procedural Guide for Combining Workstations

1. Standardized Product with Stable Demand: Use Production Line/Product Department.
   • Combine all workstations for that product.
2. Physically Large Product with Low Demand: Use Fixed Materials Location/Product Department.
   • Combine workstations in the staging area.
3. Grouped Families of Similar Parts: Use Product Family/Product Department.
   • Combine workstations for that family of products.
4. No Classifications: Use Process Department.
   • Combine identical workstations into initial planning departments.

Product Family Departments (PFD)

• Aggregate parts into families with similar manufacturing operations/design attributes.
• Cells formed through clustering of machines required for the part family.

Direct Clustering Algorithm (DCA) Methodology

Steps:

1. Order Rows and Columns
   • Sum the number of parts processed by each machine.
   • Sort rows in descending order of totals, columns in ascending order.
2. Sort Columns
   • Shift columns left based on processing for the top row.
3. Sort Rows
   • Move rows upward based on the first column.
4. Form Cells
   • Identify opportunities to group machines for parts.

Example Application of DCA

• Machines and parts matrix created.
• Steps demonstrated: Summing, ordering, sorting, and forming cells.
• Resulted in two cells for parts based on machine requirements.

Layout Types Based on Material Flow Systems

• Types of Production Planning Departments:
  1. Production Line Departments
  2. Fixed Material Location Departments
  3. Product Family Departments
  4. Process Departments

Advantages and Disadvantages of Layouts

• Production Line/Product Layout:

  • Advantages:
    • Smooth flow, reduced inventory, short production time, less skill required, simple production control.
  • Disadvantages:
    • Machine breakdown halts production, layout changes needed for new products, higher investment required.

• Fixed Product Layout (e.g., airplanes):

  • Advantages:
    • Continuity, job enrichment, highly flexible, accommodates design changes.
  • Disadvantages:
    • Increased equipment movement, requires greater skill, more space required.

• Product Family Layout:

  • Advantages:
    • Higher machine utilization, smoother flow, benefits of team atmosphere.
  • Disadvantages:
    • General supervision required, higher skill levels needed, unbalanced flow can cause issues.

• Process Layout:

  • Advantages:
    • Increased machine utilization, flexibility, diversity of tasks.
  • Disadvantages:
    • Complicated production control, increased material handling, higher skill required.

Conclusion

• Discussed departmental planning, layout types, and material flow systems.
• Understanding advantages and limitations of each layout is crucial for effective planning.