Académique Documents
Professionnel Documents
Culture Documents
Customer
Own
SAP R/3
Planned ind. Requirements (6-month rolling plan) MRP - Run
Purchasing(Converting PR to PO,GR)
Convert Planned Order to Production Order(In-House Production of Assemblies / Parts Production) Release Production Order
Confirmation & Withdrawal of Raw Material Create Production Order for Final Assembly & Assign Batch
Create Subcontracting PO (External Process) Trasfer Stock to subcontractor storage Release Assembly Orders
Pick Components
GR to Subcontracting Order Tecnical complete the Production Order for Final Assembly
C10150
Canned Beans, Labeled HERT PD
C30380 C40660
Beans Label ROH PD Canned Beans, Unlabeled PCB 2L 8B 7.6 HALB PD
C40007
Beans, Frozen ROH PD
C40650
Can ROH PD
Topics
Production Flow in High Volume Discrete Part Manufacturing Manufacturing System Layouts Manufacturing Flowlines and their variations
Synchronous Transfer Lines Asynchronous Flowlines and the Push vs. Pull dilemma Asynchronous Transfer Lines KANBAN-based Lines CONWIP-based Lines
Discrete Part Manufacturing Systems Frame Frame The end product is the Machining Painting assemblage of a Engines and Transmissions number of Seats Oil Tank Cell Cell components Steering Shocks Wheel Cell Cell and sub-assemblies, either produced inDoors Wheels Cell Cell house or procured from outside.
Packaging
Main Frame
O-2-1
O-2-2
O-2-3
A-2
A-3
O-4-1
O-4-2
O-4-3
A-4
I-1
O-5-1
O-5-2
A-5
End Product
A typical Organization of the Production Activity in High Volume Discrete Part Manufacturing
Assembly Line 1: Product Family 1
S1,1 S1,2 S1,i S1,n
S2,1
S2,2
S2,i
S2,m
Drill Workspace
Paint
Lathe Mill Mill Drill Mill Drill Grind Lathe (b) Product Layout Lathe Grind Mill Mill Drill Drill
Assembly
Saw Weld
Paint Paint
Lathe (c) Group or Cellular Layout R.M. Store Paint Lathe Lathe Drill Mill Mill Drill Assembly E.P. Store Saw Grind Weld
E.P. Store
E.P. Store
Re-entrant Lines
Flowlines in which certain processing stages share the same type of equipment, and therefore, they present re-entrance. The motivation for re-entrance and the resulting operational complexities are similar to those underlying the deployment and operation of a cellular layout. Re-entrant lines is a typical layout for semiconductor manufacturing.
Heavy Equipment
Auto assembly
Sugar refinery
A flowline classification
Flowline
Synchronous
Asynchronous Push
e.g., Asynchronous Transfer Line
Pull
e.g., KANBAN or CONWIP lines
Lots are released into the line according to an externally specified production plan. A lot that has completed processing at its current station will immediately advance to the next one.
Pull:
Target WIP levels are specified for different line segments. Lot advancements that can cause the exceeding of some target WIP levels are blocked. A drop from the target WIP level is a signal for replenishment.
Some important issues: What is the maximum throughput that is sustainable through this line? What is the expected cycle time through the line? What is the expected WIP at the different stations of the line? What is the expected utilization of the different machines? How does the adopted batch size affect the performance of the line? How do different detractors, like machine breakdowns, setups, and maintenance, affect the performance of the line?
Some important issues: What is the throughput attainable by a certain selection of KANBAN levels? What is the resulting cycle time? How do we select the KANBAN levels that will attain a desired production rate? How do we introduce the various operational detractors into the model?
Some important issues: Same as those for the KANBAN model, plus How can we compare the performance of such a system to that of an asynchronous transfer line and/or a KANBAN-based system?