Design of Operational Facilities and Systems - Case Study Example

Design of operational facilities and Systems Prepared by Submitted to Word count 3210 words (excluding content and references pages) Contents Abstract 3 1. Introduction 5 2. Facility location 5 2.1 Problems regarding the methods 4 2.2 Flow Shop 6 2.3 Problem Properties 7 3. Manufacturing systems 8 3.1 Flow and process in Manufacturing systems 8 4. Ware House Operations 9 4.1 Ware house and planning 9 4.2. Ware housing logistics 10 4.3 Ware House Management 10 5. Branch and Bound Properties 12 5.1 The process needed 12 5.2 Standard branch and bound 12 5.3 Adaptive branch and bound 13 6. Cellular Manufacturing 14 7. Material handling in Cellular Manufacturing 15 8. Lay out Designing 17 9. Strategic issues in the location of business in a global environment 19 10. References 20 Abstract The multi commodity facility location has been considered with standard mixed integer programming tools and nested partitions frame work. This is followed by flow shop activities. This contains the sequences of the machines that are included in production activities. The configuration that is advantageous than a general job shop is needed for flow shop activities. The flow shop that is capable of working more efficiently than traditional pull based manufacturing is discussed. The flow shop activities included the discussion of problem properties. This simplifies the problem situations. The optimal solution has been taken into consideration for problem properties. The manufacturing systems with discrete continuous flow had been discussed and evaluated. The comparison and evaluation should reject the failure models. The processes that avoid delays and ignorance are adopted for optimization of the processes. In the next stage the ware house operations are considered and integrating them with production and delivery activities is discussed. The inventory, logistics of the ware house operations is discussed. The need of software for warehouse operations is emphasized and its advantages in optimizing the operations execution are discussed. The outcome is that this requires integration of ware house operations with supply chain management. 1. Introduction The engineers and architects need to understand the industrial problems before designing the operational facilities for a facility. The ties between practicing community need to be strengthened to prepare material handling. Simulation modeling, group problem solving, project management and simple operational analysis is necessary for fundamental mechanical and electrical engineering principles. Strong communication, interpersonal and analytical skills need to be necessary to organize a project. The design and material handling engineer will be yet times, that of an internal consultant. To meet the needs, they have to work in multi disciplinary teams. 2. Facility Location 2.1 Problems regarding the methods: The problems regarding the multi-commodity facility location problems are generally intractable. This is in respect to standard mixed integer programming tools. Direct application of general purpose branch & cut (BC) commercial solvers are needed for solving the problems in facility locations. Nested partitions framework is capable of combining meta heuristics with MIP tools. This is including branch and cut. The alternative formulations and decomposition methods for the problem class will produce high quality solutions. When the approach is faster, the nested partitions solution will be better feasible solution than cplex. 1 2.2 Flow shop: The sequences of machines that produce the products are internal contents of a flow shop. The order they have to be processed is known as flow shop. The flow of processes and products the machines follow will go in the same direction. This requires configuration that have advantages more than a general job shop. The minimal material handling, simple conveyance between the chambers, control of activities in the chambers are an integral part of flow shop. When any incidents of back tracking of the processes occur, they can be solved easily by the simplified flow of activities. This makes the control of the flow operations easy. The modern pull based manufacturing techniques need flow shop sequences to function properly. The techniques involved in pull based manufacturing are well suited for flow shop method. The length of the resulting flow shop needs to grow with small ratio, with the number of jobs. This means that the design need to be in that manner the increase of length should not be in the proportion of the increase of jobs. The aim of the flow shop design and the activities planning should not decompose the approach for the lay out transformation. This can be refined to take advantage of symmetry. This chance of refining the process later will result in reduction of initial investment and reducing the costs for modernizing processes in future if necessary.2 2.3 Problem properties The instance of the problem is defined by the number of jobs and the number of machines. The simplification of the problem depends on the routing matrix. Generally the defined solutions cannot have more than one job routing. The implementation of one job routing matrix will decrease the time taken by the processes involved in the manufacturing. In considering solution for the problem, the direction of the length of the job needs to be considered. Then a solution can said to be feasible if the jobs processed in the considered number of machines are according to an order. Out of all the solutions the one with minimum length is termed as feasible and optimal. Though the length is less, those solutions may not describe a single routing for the jobs need to be processed. This requires more than one routing for this solution. To choose the best one among the considerations, scheduling the decisions, the finding of best routing of the job processes for the machines need to be identified. When we consider a problem, let the first property be the optimal solution of a problem context. In this context the property will be straight forward and it needs to be shown by contradiction. When a property is optimal and the first column of the routing matrix implies that there is no job to process, that one can be removed from the solution. This keeps the solution still feasible, as I column is not doing any process. 3. Manufacturing systems 3.1 Flow and process in Manufacturing Systems: The fixing of manufacturing systems need both discrete and continuous flow. The evaluation regarding performance needs throughput rate of production system. The analytical comparative study for discrete flow model of the existing failure models and avoiding them is needed. The namely operation dependant failures end time dependant failures can be analyzed for end time dependant results. There is a probability of not taking into account the delays in production, lead times and transportation that can show potential impact on performance. The negligence or ignorance of the delays cannot optimize the performance. The modeling and the impact of the delays on the throughput rate can be studied and the results can be applied in choosing or installing systems. This result from the study should be capable to address the infinitesimal perturbation analysis technique that is used to optimize our production system. The control policies considered need to be implement simulation based optimization that is capable of reducing the delays and production interruptions in the real time production process. The research focused on analysis and optimization of production distribution systems can be considered by end user ware house supplied by network of inventories. 3 4. Ware house operations: 4.1 Ware house and planning: A simple production distribution system made of one ware house supplied by a production plant is needed. The proposal of analytic approach to estimate the end customer service level will help in order to delivery lead time with the ware house. The inventory on order approach is based on queuing theory. In this process the total inventory can be graded by production systems and facilities. 4 The organizations can give importance to highly refined systems and process while planning and conducting ware house operations. There is a chance of overlooking the little things that make ware house operations efficient. The aspects that are overlooked by the organizations while planning sophisticated ware house operations are training, tools, equipment maintenance. The lack of these aspects will result in waste of time by employees. This is due to the searching of tools and being detrimental due to the lack of training. 5 4.2. Ware housing logistics: The logistics regarding ware house imply the physical distribution of the things in ware house. The ware housing needs to be dealt at par with the delivery. The ware house value based solutions are tailored to the specific supply chain processes so that the ware house operations can be connected with production and delivery processes. This transforms ware house from a cost center to a source of value. This can benefit organization from the view of marketing and delivery. 6 4.3 Ware house management: The ware house management need to be simple. The barcodes and space management is the main concern of ware house management operations. This concern used to bother the ware house managers before the advent of internet supply chain management. This web based supply chain management resulted in potential savings and gained competitive advantage. The internet technology has changed ware house dynamics and the ware house manager is able to manage the dynamics located at head office. This resulted in the speed in the operations also. The complex logistics will move at more speed by applying internet based technology in ware house operations and integrate them with delivery operations. 7 The supply chain logistics is integrated with supply chain management. This ensures the product delivered to customer according to his expectations. This can be done at lowest possible cost by adopting internet applications in ware house operations. The customer requirements and expectations need to be considered in preparing the operations for warehouse and its software. Ware house management software is needed in modern industrial facilities. This can be termed as safe and the vendor’s features also can be considered. Though no system can include all possible functionality options, but they can be maximized. The adopting of software particularly for ware house operations will decrease the gap between the standard product and the company’s needs. Up grading the software timely is a need for WMS. This can be termed as important effort in controlling the costs regarding the operations. The cost of upgrading should be lesser than the controlled cost on operations.8 The adoption of the IT solutions in the ware housing operations will integrate it to the production and delivery systems. Thus it will enhance the production flow operations and delivery systems in the marketing, making operations much easier than without the IT solutions. 5. Branch and Bound Properties 5.1 The process needed The node representation; branching scheme, bound calculation and node selection are needed for describing the branch and bound approach. Before that the non adaptive or standard branch and bound approach is discussed. It contains an approach based in properties 1-4. The second one will be more efficient and adaptive. The branch and bound algorithm taking into account properties from 1 to 5. 9 5.2 Standard branch and bound: In this solution the node will be represented by a solution. The problem and the solution will be associated with the vector. When we consider branching scheme, a node containing solution and its associated vector will be taken and set of candidates are chosen. For every machine present a solution is generated by appending the machine to the solutions. While doing this, the feasibility of the node constructed needs to be checked. When first solution feasible, the new upper bound is saved and if not the lower bound is taken into consideration. The solutions for the operational design, which have the lower bound greater than or equal to upper bound are discarded. After standard branch and bound, the adaptive branch and bound comes to the fore. 5.3 Adaptive branch and bound: The branch and bound procedure mentioned will make use of properties that are repeated with the difference of lower and upper bounds. It is to be noted that for every solution of a particular length, the lower bound will be calculated. The feasible solution adopted by us will have a length greater than lower and upper bounds. The weak and numerous nodes need to be explored before discarding them. Therefore the adaptive branch and bound procedure will present an improvement in lower bounds explicitly. In this course of improving the lower bounds, the original and inverse problems can be considered simultaneously. At this juncture every node contains a solution. For these nodes, the lower and upper bounds only are known. When the solution contains the index like the last machine in the routing matrix, the inverse problem in this contest can be included in the first set of lower bounds. 10 In this context the branching procedure needs to be modified with respect to the properties identified. In this identification process, child node was obtained by adding a machine in the last position of the parent solution. After that the appending the child node with a new machine can be decided. This starts the consideration of the beginning of the vector, that is the direction of the length of the processes and the end point. In this course of appending the considered machines and the new machine can be termed and taken as different. In the adopted procedure of flow of the process, the next machine can be appended in the position greater than the lower bound of the node. This is starting from the end of the direction of the process. In this course the inverse routing of the matrix and the processes done by the machines needed to be considered. 6. Cellular Manufacturing This is an application of group technology in the manufacturing processes construction. This involves the conversion of manufacturing system into cells. This results when the proposed production unit will have a group of dissimilar functional equipment is located. These dissimilar locations needed to be divided into cells. The cellular manufacturing will reduce the set up times. In cellular manufacturing the first phase is cell formation. This deals with the identification of the part family or families. These will associate machine groups. These machines groups will contain a cell for each. After this the cellular manufacturing constitutes the system design with previously identified and planned cells. The discussions in this case involve the equipment lay out at first.11 After that the selection and design of tooling and fixtures will be considered. The design of handling of the material is also the part of the cellular manufacturing as the handling of the materials involves the cells. In the next stage the determination of the number of machine operators, assignment of the operators to the machines or work stations is needed. The specification and capacity are taken as buffer between the work stations. The loading, scheduling, dispatching, sequencing and order quantities are considered along with the frequency of replenishment of raw materials. 12 7. Material handling in Cellular Manufacturing The first phase of cellular manufacturing needs to consider the objective economic basis. This is for the selection of the best cellular configuration and identification of the cells. The group technology configuration considers the costs of work in process. This involves cycle inventory, intra group material and handling setup. This can do the processing and considers the fixed machine costs also. The determination of the groups of parts and machines, which minimize the costs and increase cost effectiveness in the manufacturing processes is necessary. In the course of evaluation of total cost of groupings of parts and machines in Cellular manufacturing, the motivation of development of cost model is involved. 13 The cost model will take into consideration the investment on the machinery. The cost model of the cellular manufacturing will consider the machine investment, machine set up and material move cost. This will help in evaluation of total cost of a given set of cellular configurations. These cellular configurations are generated by various cellular manufacturing techniques. These will provide the cellular manufacturing techniques. These techniques will be designed according to the economic decision criteria of the alternatives considered. In the second phase of cellular manufacturing, the flexible manufacturing system model is designed. This is known as FMS. This will dimension the problem with the approach of integrated stochastic simulation. The experimental design, analysis of variance and response surface analysis are the methods employed in this stage. This approach tries to generate an flexible manufacturing system. This is done by minimizing the production of the system by evaluation of the design considering the cost function. If the cost of the product increases with production, the design suggests the reduction or enhancement in the production. The relevant decision can be taken by considering the suggested proposals. In this method, the costs are minimized by the combinations needed for the production requirements. The conflicting nature of both performances, production and cost will result in calculating the minimum cost design. Even the comparison will be complicated. This is due to the existence of incommensurable units. The method involved in the above processes cannot evaluate the profitability of the design. This would make the design selection process simpler by having less responses in terms of cash. To minimize the affects of the flexible automations systems and structure, evaluation of the multi machine system can be adopted in the cellular manufacturing. These configurations physically and economically needed to be considered simultaneously. The DSS structure needs to integrate various analytical, experimental and rule methods to evaluate configurations of multi machine system. 8. Lay out Designing The method consists of four sequences in phases. They are modeling, experimentation, analysis and evaluation. The modeling phase summarizes and integrates the information. The experimental phase will guide the search for relationships. The analysis phase will enable the user to put forth the relationships mentioned above to create different solutions. In the evaluation phase, the identification and confirmation of the most profitable solutions as well as the selection of final design for cellular manufacturing is done. The modeling phase will include the factors that are controllable and non controllable. They are likely to have an impact in the profitability of the cell for the study. The uncontrollable factors are termed as noise factors throughout the study. The controlling factors will have influence on the independent variables. The factors influence the dependent variables have the capability adjusted with the objective. This will minimize or maximize the response according to the need. In this phase it is necessary to define the controlling factors of the processes. This is because; these are capable of impacting the profitability of the system. These vary with the experiment. These are also necessary to specify the ranges over which these factors can be varied.14 The experience in the cellular manufacturing and modeling it is needed to select the control factors. This is because the uncontrollable factors are to be eliminated. If any uncontrollable factor is identified as controllable factor, the whole process of cellular manufacturing will be rendered useless as it looses its cost effectiveness in the processing the jobs. This consists of deciding the production levels, inventory levels, operations expenses, equipment expenses and the manufacturing of the cell. The above figure is adopted from http://www-iwse.eng.ohio-state.edu/ISEFaculty/IRANI/research/Papers/Paper%20-Desing%20of%20MC%20under%20Economic%20Considerations.doc 9. Strategic issues in the location of business in a global environment The strategic roles of the companies are different for various geographic locations. The relationships between the companies and their performance depend upon the location. The location up to some extent will effect the degree of the performance in global environment of the business. The companies in seeking the location want to maximize the world wide performance.15 This should be done through integration and they have to select locations according to their potential contribution to total corporate benefits. The companies need to reduce the cost and develop cost effectiveness by product standardization. When companies want to locate a company in a place, the things the people there want to buy need to be known by the company. The diminishing differences between countries, increasing economies of scale, improvements in transportation and communication and increasing homogenization and needs among countries will be considered while deciding the location. 16 10. References 1. Stanley F. 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