OPERATIONS MANAGEMENT

NOMBRE:Liliana Gualotuña

Course: 9th Industrial

EL ANÁLISIS Y COMPRENSIÓN DE MATERIALES BIBLIOGRÁFICOS Y

DOCUMENTARIES: TRANSFORMATION PROCESSES IN THE CHAIN OF
SUPPLIES.

What is plant layout?

The layout is the physical arrangement of machines and equipment for production, stations
of work, personal, location of materials of all kinds and at all stages of production,
and the materials handling team. The plant layout is the final result of
design project of the manufacturing facility.

What is facility design?

The design of manufacturing facilities refers to the organization of the facilities.

company's physical resources in order to promote the efficient use of its resources, such as
personnel, team, materials, and energy.

What is material handling?

It is simply defined as moving material; however, the use of this equipment must
be justified by the decrease in labor and increase in volume of
production, that is to say, it must make the investment worthwhile which is generally expensive (Return of

investment

4. Explain how the cost reduction formula is used in the design process.
manufacture.
 QUESTION FOR EVERYTHING THEREFORE, BE
CAN
Why? Operation remove
Who? Transport combine
What? Inspection change the sequence
Where? storage simplify
When?
How?

The facility planners ask the six questions (column 1) about everything that
can happen to an element that flows through the manufacturing plant (column 2) for
eliminate stages, combine them, change their sequence or simplify them (column 3). This requires
study in depth the company's products in order to identify each stage of the
process.

5. What is the percentage of injuries and the operation costs it causes?

material management?

Material handling causes approximately 50 percent of all

accidents, and between 40 and 80 percent of all operating costs

6. Make a list of the goals for the design of manufacturing and handling facilities.
of materials.

Minimize unit and project costs.

Optimize quality.
Promote the effective use of a) personnel, b) equipment, c) space, and d) energy.
Provide to the employees
convenience
b) security, and
c) comfort.
Control the project costs.
 Reach the start date of production.
Give flexibility to the plan.
Reduce or eliminate excessive inventories.
Achieve several goals.

7. What is the mission statement?

It consists of a philosophical statement that sets the cultural tone of the organization.
A mission statement communicates the primary goals and culture of the organization to
facilities planner. The mission statement defines the purpose for which
the company exists.

8. What are the two concepts in figure 1-1 that exhibit delays in relation
with the scheduled plans?

Establish time standards and Design workstations.

9. What is the value of the manufacturing facilities design procedure?

The manufacturing facility design procedure is a general plan of the

project. Each stage will include some techniques that will not be used in all situations.
Skipping stages is allowed if it is considered that they are not necessary.

The quality of the design of a manufacturing facility (layout of the distribution of

plant) depends on how well the planner collects and analyzes the basic data. The plan
it is the final stage of the design process and the one with which beginners in planning
They want to start.

10. Make a list of the manufacturing facility design procedure.

The following is a systematic way of thinking about a project.

1. Determine what will be produced; for example, a toolbox, a case of

give or a mower.
2. Calculate how many items will be produced per unit of time; for example, 1,500 per
8-hour shift.
3. Define which parts will be manufactured or purchased finished - some companies
They acquire all the parts and are called assembly plants. The parts that the company
factories require manufacturing equipment and a considerable amount of additional
design work.
4. Determine how each part will be manufactured. This is called process planning and
it is usually carried out by a manufacturing engineer, but in many projects the
manufacturing facilities designer is also responsible for the design of
tools, equipment, and workstations.
5. Determine the assembly sequence. This is called line balancing.
assembly.
6. Establish time standards for each operation. It is impossible to design a
plant distribution without time standards.
7. Determine the rate of the plant (processing time). That is, how fast is it
it needs to produce. For example, it requires making 1,500 units in eight hours (480
minutes), so 480 minutes divided by 1,500 units equals .32 minutes.
The speed of the plant and of each operation within it must produce a part every
.32 minutes (approximately three parts per minute).
8. Calculate the number of machines needed. Once the plant rate is known.
and the standard time for each operation, you must divide the standard time by the rate
of line and the result is the number of machines. For example, you have an operation
with a standard time of 75 minutes and a line rate of 32 minutes.
How many machines are needed (Is 75 divided by 32 equal to 2? 34 machines)?
You will need to buy three machines. If you only acquired two, you would never produce 1,500 units.
per shift without working overtime. This will cause a bottleneck.
9. Balancing assembly lines or work cells. This is about dividing the work among the
assemblers or cell operators according to the line rate. To the extent that
If possible, I tried to give each one the same amount of work.
10. Study the material flow patterns to establish which is the best (the distance
shorter through the installation).
a. Chain diagram.
b. Multiple product process graph.
c. Origin-destination graphic.

d. Process graph.
e. Flowchart of the process.
f. Flowchart.
Determine the relationships between activities—how close they need to be
Departments one from another in order to minimize the movement of people and materials?
12. Make the layout of each workstation. These layouts will lead to
the department's, and then to the entire installation.
13. Identify the service needs for staff and the plant, and provide the
required space.
14. Identify the office needs and make the necessary arrangements.
15. Develop the total space requirements based on the previous information.
16. Select the material handling equipment.
17. Assign the area according to the necessary space and the relationships of activities
established in point 11.
18. Develop a graphic plan and the form of construction. How does it fit the
installation on the ground?

19. Build a master plan. This is the design of the manufacturing facility—
last page of the project and the result of all the collected data and the decisions
taken during the previous months.
20. Find faults and adjust. Ask your fellow engineers and managers.
level that yours to review their plan to see if they can detect design errors beforehand
I present it to the management for approval.
21. Seek approvals, accept advice, and change what is necessary.
22. Install the distribution. At this stage, the plan materializes and it is one of the moments
more satisfying and also one of the most tense.
23. Start production. Anticipate that many things will go wrong. No one has
Started a production line without any problems; do not expect to be the first.
It will get better every time, but it will never be perfect.
24. Adjust what is necessary and finalize the project and budget performance report.

11. What are the five types of facility design projects?

manufacture?

1. New installation. This is by far the most fun job and where you can have
the greatest influence on the design of a new manufacturing facility. In a
new project there are few restrictions and limitations because it doesn't have to worry about
the old facilities.

New product. The company allocates a corner of the plant for a new product.
The new product must be integrated into the flow of the rest of the plant, and certain equipment in
common perhaps they will be shared with the existing products.

3. Changes in design. Changes in the product design are always made to

improve its cost and quality. Distribution could be affected by such changes.
and the installation designer must review each design modification.

Reduction of cost. The designer of the plant facilities could find

a distribution that would produce more units with less effort from the
workers. Other people in the company could make suggestions for improvements and
cost reductions that affect distribution. All of this must be taken into account.

5. Retro adjustment. Due to the fact that many old plants have poor layouts,
the designers of old manufacturing facilities may spend most of their
time working to make them more productive.

12. What is the difference between the procedures for designing a facility?
new and a retro adjustment?

The procedure for the retrofitting is the same as for a new plant—except that there is
more restrictions. These include: existing walls, moats, low ceilings and
any other permanent arrangements that represent an obstacle to the efficient flow of
the materials.
13. What is lean manufacturing and lean thinking?

Lean manufacturing is a concept through which all personnel

production works together to eliminate waste. Industrial engineers,
industry technologists, and other groups within the administration, have been trying to do it
anterior since the beginning of the industrial revolution, but with the advent of a force of
well-educated and motivated production work, modern manufacturing management has
discovered the advantages of seeking help in waste removal.

14. Defina muda, kaizen, kanban y andon.

Muda (waste): it is defined as any expense that does not help to produce value. There is
eight classes of waste: overproduction, waste, transportation, processing,
inventory, movement, repetitions, and inefficient use of personnel.

Kaizen (Constant or Continuous Improvement). The main element of kaizen is the people.
involved in the improvement process. Kaizen includes all levels of the organization
and requires the participation of all employees.

Kanban: it is a signal board that communicates the need for material and indicates in
visual form to the operator that produces another unit or quantity. The kanban system, also
known as a pull system, differs from traditional inventory systems that
"push", such as just in time (JIT) or requirements planning
materials (MRP).

Andon: It is the method of indicator boards to stop the work that is above
the production line and serve as visual control. When the operations are
Normal, the green light is on. A yellow light turns on when an operator
wants to adjust something or asks for help. If the line needs to stop to resolve the issue,
a red light turns on.

15. Define simulation and explain why you think it can be a tool.
important in the design of facilities.
Simulation: This is a means of experimentation with a detailed model that represents the
characteristics of real systems, to determine how the system will respond to various
changes in its components, environment, and structure. For our purposes, it can be defined as a
system as a work cell, assembly line, group of machines, or complete installation
of manufacturing. The simulation provides the opportunity to have a series of games of the type
"What would happen if..." and observing the effects of different changes or manipulations in the model.
to optimize or improve the real system.

16. Explain how you would incorporate the different requirements of ISO 9000 in the
planning process of the facilities.

In order to incorporate and facilitate the implementation of these standards, the following must be taken into account:

necessary provisions during the initial planning of the facilities. The most recent review
the ISO 9000 standard emphasizes 'the process approach' for the organization of
company. When analyzing the planning of facilities with a macroscopic approach, everyone and
each of the aspects of the company—from reception to shipping, with all the
functions and the intermediate supports of the installation - must operate as a system
integrated and cohesive that supports the process. Some particularities are as follows.

17. What do you think the term 'random' means? Give an example of it on the floor of
the factory and how simulation could help to understand this phenomenon.

Random processes are those events that occur without any warning or
pre-planning, like a machine failure. Simulation is used both to understand how
to better prepare for such events.

18. Are you familiar with any automatic data capture technology?
Where and how do you see this technology being applicable in the planning process?
of facilities?

The most common devices are readers and scanners used to count the items in the
supermarkets. In the plant, they engage in various activities, such as material handling
para controlar los inventarios, los trabajos en proceso, el estado del equipo, etcétera.
19. On average, an installation for some design changes of the
Distribution happens every 18 months. What would such changes require?

These changes are necessary due to changes in the product; increase or

decrease in the volume of production, and add, change, or remove various
operations and processes of activities in the workshops.