2. Interfaces Flashcards
(18 cards)
What is the Theory of Swift and Even Flow explaining?
The Theory of Swift and Even Flow, often associated with lean manufacturing and just-in-time principles, explains that efficiency and productivity are maximized when materials and information move quickly and smoothly through a system without interruptions. It emphasizes reducing variability, bottlenecks, and work-in-process inventory to achieve a continuous, uninterrupted flow. The core idea is that swift and even progress minimizes waste, shortens lead times, and improves overall system performance, leading to lower costs and higher quality.
Theory of Swift and Even Flow example
In a car manufacturing plant, if the assembly line moves quickly and consistently (swift and even flow) without bottlenecks or unpredictable delays (low variability), the plant’s productivity (number of cars produced per hour) will be higher. Conversely, if there are frequent stops or changes in production speed, productivity will decrease.
TSEF Theory of even flow, law of variability
More variability, the less productivity
TSEF Theory of even flow, law of bottlenecks
Eliminating bottlenecks, better productivity
TSEF Theory of even flow, law of scientific methods
More productivity of labor by applying Scientific management movement methods
TSEF Theory of even flow, law of quality
More quality more productivity as waste declines
TSEF Theory of even flow, factory focus
Factories with a limited set of tasks will be more productive than similar factories with broader array of tasks. For example, dedicating a factory for bolt foundry instead of manufacturing all elements of a watch in house.
What is the difference between location and layout planning?
Location planning determines the geographic placement of a facility, such as a factory or warehouse, considering factors like proximity to markets, suppliers, labor, and transportation infrastructure. It’s a strategic, long-term decision impacting the entire supply chain. For example, locating a factory in Mexico due to the proximity to the USA or keep in China despite the tariffs. And within Mexico, which city.
In contrast, layout planning focuses on the physical arrangement of departments, workstations, and equipment within an existing or planned facility. It’s an operational decision aimed at optimizing material flow, communication, and efficiency within the chosen location. For example, in an anode electrode line, the process required is to mix, coat, dry, calender and slit. The machines should be placed in a way to minimize the distances between the operations.
Example: A company deciding where to build a new factory (e.g., in Italy or Germany) is engaged in location planning. Once the location is chosen, deciding how to arrange the machines, workstations, and material flow within that factory building to minimize transport costs is layout planning.
How can layout planning be defined?
Layout planning has the task to arrange the locations of machines and equipment of production processes on site so that the transport costs are minimized.
This task is very complex and depends on influencing factors like lot sizes, methods of production (assembly line production, workshop production) or the transportation facilities.
For layout planning, many areas of expertise (engineering, logistics, architecture,….) have to be considered to guarantee the feasibility of the layout.
Layout planning shall guarantee the design of an optimal material flow through the plant (work systems involved in the process are installed at the optimal location) despite changing to new location, re-setting and expansion.
Example: For a bakery, layout planning would involve determining the best arrangement of the ovens, mixers, proofing stations, and packaging areas within the bakery space to ensure a smooth flow of ingredients to finished products, reducing unnecessary movement and transport of goods
Which sub-elements are there to the general objective of cost minimization in layout planning?
Transport cost
Temporary storage costs
Relocation costs
Susceptibility to failure
Cost minimization in plant layout: Define transport costs
includes raw materials, between receiving area and manufacturing, intermediate and final products, waste and rejected products between manufacturing and storage in dispatching area. Labor and administration, means of production, space and repair and maintenance are also considered.
Example: Designing a factory layout so that the raw material storage is directly adjacent to the first processing step, and subsequent processing steps are arranged in a linear fashion, thereby reducing the distance materials need to be transported.
Cost minimization in plant layout: define temporary storage
Can be caused by process design or disfunction
Complementary to the minimization of the transport costs, as if that is achieved, this one will too
Includes energy, interest charges, insurances and labor
Example: A “just-in-time” inventory system that minimizes the need for large intermediate storage areas between production stages, thus reducing associated costs.
Cost minimization in plant layout: define Relocation costs
The layout must be planned and built in a manner so that future changes in production program will have low resetting and relocation costs - long term minimization of relocation costs.
Comprises: build and setup costs, transport, training and labor
Example: Designing modular workstations that can be easily reconfigured or moved with minimal expense if the product line changes or production volume shifts.
Cost minimization in plant layout: Define minimization of susceptibility
This is in conflict with the minimization of the transport costs, as can it lead to a clear arrangement and therefore higher transport costs.
Min susceptibility is reached if transport routes are non-overlaping or opposing. Causing a reduction of repair and hold-up costs.
Labor cost may decrease due to less facilities supervised.
Example: Clearly marked, one-way paths for forklifts and personnel within a warehouse to prevent collisions and congestion, even if it means slightly longer routes for some movements.
Please describe the stepwise approach of the triangulation method.
Starting point the intensity matrix (slide 25) we will determine:
- Layout center: two facilities with the highest intensity (or intensity sum) . FA 2 and 3 will be the center: I23=15
- Choice of the facility which shall be placed next: facility with the highest intensity towards an already positioned facility.
We have FA2 and FA3 in place.
We compare FA1 to FA2 and FA3 that gives: I12+I13=8
We compare FA4 to FA2 and FA3 that gives: I24 + I34 = 9.
FA4 shall be placed next between FA2 and FA3
- Positioning of the facilities within the existing layout: maximum sum of intensities towards the neighbouring facilities in the layout or minimum sum of the transport performance number (transport quantity x route).
We have 3 possible choices to place FA1:
A) between FA2 and FA3: I12+I13=8
B) between FA2 and FA4: I12 + I14 = 5
C) between FA3 and FA4: I13+I14=7
We choose A.
Final layout on slide 27.
Elaborate on advantages and disadvantages of the triangulation method.
Advantages
▪ Easily understandable and an applicable opening solution
▪ Low calculation effort
▪ Layout is established, step by step
Disadvantages
▪The more items are positioned, the higher the resulting requirement for improvement
▪The optimization can only be handled with software support
▪Further criteria, e.g., the utilization of space, are not considered in the triangulation method
Name three application fields for facility layout planning.
Manufacturing plants, where it optimizes production lines and material flow
Retail stores, where it focuses on customer traffic patterns and product display for sales maximization
Healthcare facilities, such as hospitals or clinics, where it aims to improve patient flow, staff efficiency, and accessibility of medical equipment and services.
It is also crucial for warehouses and distribution centers to maximize storage capacity and optimize order fulfillment.
Researchers from China presented an effective and flexible computer model for subsea oil gathering-transportation system layout design optimization. It determines pipeline topology, routes, and facility sizes, integrating obstacles and intersection avoidance, minimizing total cost.
