Module 2rrv 2part Essay

Submitted By RogerHern
Words: 907
Pages: 4

Chapter 2:

Product, Process, & Schedule Design
Dr. Rosario Rosas-Vega
IE 4355 : Facilities Design
Texas State University

Schedule Design

Schedule design decisions provide answers to questions involving how much to produce and when to produce.
Production quantity decisions are referred to as lot size decisions.
Determining when to produce is referred to as production scheduling.
How low production will continue?

Impact of Schedule Design
1. Machine selection
2. Number of machines 3. Number of shifts
4. Number of employees 5. Space requirements 6. Storage equipment


Material handling equipment


Personnel requirements


Storage policies


Unit load design


Building size

Schedule Design

Process Requirements

Process design determines the specific equipment types required to produce the product. Schedule design determines the number of each equipment type required to meet the production schedule Specification of process requirements typically occurs in 3 phases:

Quantity of components to be produced including scrap Equipment requirements for each operation
Combine the operation requirements

Calculation Production Requirements

Operation k Ok= Ik (1-dk) dkIk 


dk = percentage of defective items produced on the kth operation. Ok = desired output without defects

Ik = production input

On the average:

For products with n sequential operations:

• A product has a market estimate of 97000 components and requires three processing steps (turning, milling, and drilling) having scrap estimates of d1=0.04, d2 =0.01, and d3=0.03. What is the expected number of units to start

Ik = Ok /(1-dk)

I3 = 97000 /(1-0.03)=100,000

I2 = 100,000 /(1-0.01)=101,000
I1 = 101,000 /(1-0.04)
I1 = On /[(1-P1) (1-P2)…(1-Pn)]=
I1 = 97000/[(1-0.04) (1-0.01)(1-0.03)]=105,219

Productions Requirements with Rework

The end product requirement is 100,000 pieces. Given that rework is performed, calculate the number of units required for processing at the first operation. Assume that the defective rates (in decimal) are d1= 0.03, d2 = 0.4, and d3 = 0.02.
I1 
0.98 0.97  0.03 0.60  

Equipment Fractions

Quantity of equipment required for an operation. F=SQ/HER
F = number of machines required per shift.
S = standard time (minutes) per unit produced. Q = number of units to be produced per shift. E = actual performance (%of standard time). H = amount of time (minutes) available/machine. R= machine reliability (% uptime).


A machined part has a standard machining time of 2.8 minutes per part on a milling machine. During the eight-hour shift, 200 units are to be produced. Of the 480 minutes available for production, the milling machine will be operational 80% of the time. During the time the machine is operational, parts are produced at a rate equal to 95% of the standard rate. How many milling machines are required?

F=number of machines per shift
S=2.8 minutes per unit
Q=200 units per 480 minutes
H=480 minutes /shift.

F=SQ/HER=2.8(200)/0.95(480)(0.80) =1.535 machines per shift Facilities Design

7 Management and Planning Tools

Affinity Diagrams
Interrelationship Digraphs
Tree Diagrams
Matrix Diagrams
Contingency Diagram
Activity Network Diagram
Prioritization Matrix

Affinity Diagram

Gather and organize ideas and issues into groupings.

Uses techniques like brainstorming to get suggestions on how to solve the problems.

Interrelationship Digraph

Sequence of steps often comes from this activity.
Maps logical links among related items from Affinity Diagram.
Helps identify which items impact others the most .

Tree Diagram

Maps in increasing detail the actions that need to be accomplished in order to achieve a general objective

Matrix Diagram

Organizes information into sets for