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Lecture 5

Production Flow Analysis

1

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2

1111111111222222222233333333334444

1234567890123456789012345678901234567890123

1 1 1

2 1 1 1 1 11 1 1

3 1 1 111

4 1 1 1 1 1 1 1

5 1 11 111 1 1 1 1 1 1 16 11 111 111 1 1 1 111 1 11 117 1 1 1

8 111 11 11 111 11 11 1 11 1 19 1 1 1 1 1 1 11 1 1

10 1 11 11 1 1

11 1 1 1 1 1 1

12 1 1 1 1 1

13 1 114 1 1 1 1

15 1 1 1 1 1 1 116 1 1 1 1 11 1

King and Nakornchai, 1982

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3

Machines 1 2 3 4 5 6 7

123

456789

101112131415

16

285

7131931910

765247

7

065

713173188

765247

5

065

713173168

744047

5

065

713150158

444047

5

065

713130138

044047

5

065

612130108

002047

5

065

61213098

000047

5

Frequency table

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4

Machines 37 42

1

2

6

8

9

16

* *

* *

* *

*

* *

* *

Module 1 - Machine 1 as nucleus

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5

Machines 3 24

13

8

11

12

* *

* *

* *

*

Module 2 - Machine 13 as nucleus

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6

Modules Machines Components

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

1 2 6 8 9 16

13 8 11 12

7 6 8 10

10 6 8

11 4 5 8 12

12 8

14 2 6 8 9 16 3

3 6 16

16 2 9 6 8

2 8 9 6

9

4 5 15 6 8

6 5 8 15

15 5 8

8 5

5

37 42

3 24

1 13 25

12 26 31 39

9 20 27 30

11 22

2 6 17 35

7 34 36

10 8 32 38

28 40

4

5 14 19 21 23 29

8 33 43

41

15

16

Modules for the given matrix

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Module Machines Components

1

2

34

5

6

1 2 6 8 9 16

8 11 13 12

6 7 8 104 5 8 11 12

2 6 8 9 14 16 3

4 5 15 6 8

4 28 40 10 18 32 38 37 42

11 22 3 24

12 26 31 39 1 13 259 20 27 30

7 34 36 2 6 17 35

16 15 41 8 33 43 5 14 19 21 23 29

Modules after merger

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7 34 36 2 6 17 35

2 *6 * * * * *

8 *9 *14 * * * * *

16 *

3 * * * * *

Component 2 goes to machine

cell (1,2,6,8,9,16). Intercell move 2-14

Remove

component 2

Components

6, 7, 17, 34, 35

and 36 need

machines3, 6, 14

We save 4

machines

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9 20 27 30

4 *

5 *

8 * * *

11 * * * *

12 * *

Remove

component 9

Components 20, 27, 30 go to

machine cell (8,11, 12, 13).

Component

9 goes to machine

cell (4,5,6, 8,15)

Component 9

visits machine 11

in cell (8, 11, 12, 13)

We eliminate this cell!

And create 1 intercell

move

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11233344 1333 1111222344 112233 122223

2408827802677456589456913931312356193102470

1 1 1

2 1 1 111111

9 111111111

16 1 11 111 1

3 11111

14 1 1 1 1

4 1 11 11111

5 1111111111111

6 1 11 111111 1 11 1 1 1 111 1

8 1 1 11 111 1 111 111 1 111 11

15 1 1 11 111

7 11110 111111

11 1 1 1 111

12 1 1111

13 1 1

Final block diagonal structure

Intercell move after duplicating 6 and 8

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Final Solution 5 cells

Machines 6 and 8 - 4 each required

2 intercell moves

Capacity Planning

Cell Layout

Processing times

Set up times

Volumes

Number of machines available

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Lecture 6 Capacity Planning

Layout

Exercise on PFA

Reducing Intercell moves

13

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14

11233344 1333 1111222344 112233 122223

2408827802677456589456913931312356193102470

1 1 1

2 1 1 111111

9 111111111

16 1 11 111 1

3 11111

14 1 1 1 1

4 1 11 11111

5 1111111111111

6 1 11 111111 1 11 1 1 1 111 1

8 1 1 11 111 1 111 111 1 111 11

15 1 1 11 111

7 111

10 111111

11 1 1 1 111

12 1 1111

13 1 1

Final block diagonal structure

Intercell move after duplicating 6 and 8

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Let the volume of part j per year = dj. Let the unitprocessing time for part j on machine i is pij. The timerequired on machine i per year for part j = pijdj

Let the time available on machine i per year = Ai. If theorganization works 6 days a week for 16 hours a day,the time available per year is 4992 hours. Ai= k times

4992 where can be 70 to 80% and includes set up timesand other non available times.

The number of type I machines required to make the

volume of part j is given by

is a fraction. Usually, 0 aij 1

15

i

jij

ijA

dpa

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16

1 2 3 4 5 6 7 81 1 1 2 22 1 3 1 23 2 2 14 3 1 45 2 1 3 2 36 4 3 2 3 3 1

Unidirectional flow

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17

Group

No.Machines Parts

1 3, 1, 4, 5, 6 1, 4, 5, 63 2, 5, 6 2, 3, 7, 8

2 cells

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1

6

6

3

2

4

5

Cell 1 Cell 2

6

5

P1

P4

P5

1

4P6

P2, P3, P7

P8

Extra machines

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Lecture 7 Exercise on PFA

Reducing Intercell moves

Rank Order Clustering

19

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Exercise

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 TOT

UNU

TILIS

No.

of

A 10 8 18 10 20 15 20 15 30 146 54 2

B 30 20 15 30 25 30 20 25 20 40 255 45 3

C 20 20 16 19 20 25 20 30 20 190 10 2

D 30 40 20 10 20 30 20 170 30 2

E 10 20 20 15 15 20 100 0 1

F 15 20 20 15 20 15 15 20 140 -40 1

G 10 20 10 20 60 40 1

H 30 20 20 20 90 10 1

I 10 15 15 10 50 50 1J 10 20 15 15 60 40 1

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1 2 3 4 5 6 7 8 9

1

0

1

1

1

2

1

3

1

4

1

5

1

6

1

7

1

8

1

9

2

0

A 1 1 1 1 1 1 1 1 1

B 1 1 1 1 1 1 1 1 1 1

C 1 1 1 1 1 1 1 1 1

D 1 1 1 1 1 1 1

E 1 1 1 1 1 1

F 1 1 1 1 1 1 1 1

G 1 1 1 1

H 1 1 1 1

I 1 1 1 1

J 1 1 1 1 1

PRODUCTION FLOW ANALYSIS

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Nucleus G H I J F D E

1 2 3 4 5 6 7 8

A 9 6 5 5 5 4 3 0

B 10 9 7 5 5 4 3 0

C 9 5 4 4 4 4 3 0

D 7 7 6 3 2 1 0 0

E 6 6 6 5 4 3 3 0

F 8 8 4 4 2 0 0 0

G 4 0 0 0 0 0 0 0

H 4 4 0 0 0 0 0 0

I 4 4 4 0 0 0 0 0

J 5 5 5 2 0 0 0 0

PRODUCTION FLOW ANALYSIS

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MODUL

E1 Nucleus Machine "G"

Machin

es 3 5 10 12A * * *

B *

C * * * *

G * * * *

MODULE

-2: Nucleus Machine "H"

Machine 6 8 11 18

A *

B * * *

C *

D *

F * * * *

H

*

*

*

*

MODULE

-3: Nucleus Machine "I"

Machine 4 9 14 20

B * *

D * * *

E *

I * * * *

J * * *

MODULE-

4: Nucleus Machine "J"

Machine 2 7

D *

E *

F * *

J * *

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MODULE-5: Nucleus Machine "F"

Machine 13 15

A *

B *

D *

E *

F * *

MODULE-

6: Nucleus Machine "D"

Machine 16

A *

B *

C *

D *

MODULE-7: Nucleus Machine "E"

Machine 1 17 19

A * * *

B * * *

C * * *

E * * *

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1 A, B, C, G 3, 5, 10, 12

2 A, B, C, D, F, H 6, 8, 11, 18

3 B, D, E, I, J 4, 9, 14, 20

4 D, E, F, J 2, 7

5 A, B, D, E, F 13, 15

6 A, B, C, D 16

7 A, B, C, E 1, 17, 19


1 A, B, C, G 3, 5, 10, 12, 1, 17, 19

2 A, B, C, D, F, H 6, 8, 11, 18, 16

3 B, D, E, I, J 4, 9, 14, 20

4 D, E, F, J 2, 7

5 A, B, D, E, F 13, 15

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1 A, B, C, G 3, 5, 10, 12, 1, 17, 19

2 A, B, C, D, F, H 6, 8, 11, 18, 16, 13, 15

3

B, D, E, I, J

4, 9, 14, 20, 2, 7

5 A, B, D, E, F 13, 15

Using interchangeability of machines

F and I are interchangeable. Merge modules 3 and 4

C13 requires A, E, F and C15 requires B, D, FC15 goes to module 2C13 goes to module 2 with 1 IC move.Remove module 5

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Modules Machine Load Components

1 A =91, B=110, C=151, G=105 3, 5, 10, 12, 1, 17, 19

2

A=55, B=85, C=39, D=60, F=105,

H=90

6, 8, 11, 18, 16, 13, 15

3 B = 60, D = 110, E=40, I=85, J=80 4, 9, 14, 20, 2, 7

Using interchangeability of machines

Modules Machine Load Components

1 2A , 2B, 2C, 2G 3, 5, 10, 12, 1, 17, 192 A, B, C, D, 2F, 2H 6, 8, 11, 18, 16, 13, 15

3 B, 2D, E, I, J 4, 9, 14, 20, 2, 7

Avaliability = 85%

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28

No. Machine Total

Load

Available Required

1 A 146 2 3

2 B 255 3 4

3 C 190 2 3

4 D 170 2 3

5 E 100 1 1 + 1 (IC)

6 F 140 1 2

7 G 60 1 2

8 H 90 1 2

9 I 50 1 110 J 80 1 1

E + G = 100 + 60 = 160F + I = 140 + 50 = 190H + J = 90 + 80 = 170

8 new machinesRequired. Cost = 160

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29

No. Intercell moves Loads after IC Required Available Utilization

1 A to A 71 + 75 2 2

2 B to B 80 + 85 + 90 3 3 90

3 3 moves C to C 91 + 99 2 2 99

4 D to D 90 + 80 2 2 90

5 F to I 90 + 100 1+1 1 + 1 100

6 G to E 85 + 75 (IC) 1 + 1 1 + 1

8 IC moves; Cost = 4 lakhs

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30

MODULES M/C COMPONENTS

1 A,B,C,D,E,F,H 1,6,7,8,11,13,15,16,17,18,19

2 B,D,E,F,I,J 2,4,9,14,20

3 A,B,C,G 3,5,10,12

Another solution


1 2A,2B,2C,2D,E,F,H 1,6,7,8,11,13,15,16,17,18,19

2 B,D,E,F,I,J 2,4,9,14,20

3 A,B,C,G 3,5,10,12

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31

No. Machine Total

Load

Available Required

1 A 146 2 3

2 B 255 3 4

3 C 190 2 3

4 D 170 2 3

5 E 100 1 2

6 F 140 1 2

7 G 60 1 1

8 H 90 1 2

9 I 50 1 110 J 80 1 1

E + G = 100 + 60 = 160F + I = 140 + 50 = 190H + J = 90 + 80 = 170

7 new machinesRequired. Cost = 140

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32


1 A,B,C,D,E,F,H1,2, 4,

6,7,8,11,13,15,16,17,18,19

2 B,D,E,F,I,J ,9,14,20

3 A,B,C,G 3,5,10,12

Another solution

No. Intercell moves Loads after IC Required Available Utilization

1 A to A 90 + 81 2 2

2 B to B 180 + 90 3 3 90

3 C to C 89 + 76 2 2 89

4 D to D 90 + 80 2 2 90

5 F to I 90 + 100 1+1 1 + 1 100

6 E to E (2) 100 1 1

7 IC moves; Cost = 3.5 lakhs

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Critical tradeoffs in cell design Large cell sizefewer extra machines

Extra machines Vs intercell moves

Reducing intercell moves Cost vs utilization

Does PFA give the best solution?

Algorithmic version of PFA

Optimization (Minimize IC moves) (with andwithout line analysis)

33

Documents

5, 6, 7 Pfa