Machine-part matrix - Designing a Cellular Layout -

FLOW, SPACE, AND ACTIVITY RELATIONSHIPS

EIN4364 Chapter 3 - Flow, Space, and Activity Relationships 1

Designing a Cellular Layout

Original process layout Notice:

The distance that each part must travel before completion The irregularity of the part routings Amount of paperwork needed to direct the flow of each individual part and to confirm that the right operation has been performed

EIN4364

Chapter 3 - Flow, Space, and Activity Relationships

Designing a Cellular Layout

In its current form, there is no apparent pattern to the routings. Let us reorder part routing matrices to identify families of parts with similar processing requirements.

EIN4364

Chapter 3 - Flow, Space, and Activity Relationships

Designing a Cellular Layout

Part routing matrix reordered to highlight cells Revised Layout with three cells

EIN4364

Chapter 3 - Flow, Space, and Activity Relationships

Direct Clustering Algorithm (DCA)

1. 2.

3.

4.

5.
6.

Sum the 1s in each column and in each row of the machinepart matrix. Order the rows in descending order of the number of 1s in the rows. Break the ties in descending numerical sequence. Order the columns in ascending order of the number of 1s in each. Break the ties in descending numerical sequence. Beginning with the first row, shift to the left of the matrix all columns having 1 in the first row. Continue row-by-row until there is no further opportunity exists for shifting the columns. Column-by-column, beginning with the left most column, shift rows upward to form blocks of 1. Form cells.
Chapter 3 - Flow, Space, and Activity Relationships 5

EIN4364

DCA: example
Part # Machine #

1 1
1

3 1

1
2 3 4 5 6

1 1 1 1

EIN4364

Chapter 3 - Flow, Space, and Activity Relationships

1. Sum the 1s in each column and in each row of the machine-part matrix.
Part # Machine #

1 1
1

3 1

# of 1s 2
1

1
2 3 4 5 6 # of 1s

1 1 1 1

3 2 1

1 3 2 2 2

1 2

Order the rows in descending order of the number of 1s in the rows.

EIN4364

Chapter 3 - Flow, Space, and Activity Relationships

2. Order the rows in descending order of the number of 1s in the rows.

Part # Machine #

2 1

4 1
1

5 1
1

# of 1s 3
2 2 2 1 1

3
6 4 1 5 2 # of 1s 1 3 1 1

1 1 1 2 2 2 2

Order the columns in ascending order of the number of 1s in each.

EIN4364

Chapter 3 - Flow, Space, and Activity Relationships

3. Order the columns in ascending order of the number of 1s in each.

Part # Machine #

5 1
1

4 1
1

2 1

# of 1s 3
2

3
6 4 1 5 2 # of 1s

1 1 1

1 1 1

2 2 1 1

Row-by-row, shift to the left of the matrix all columns having 1 in the first row.
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4. Row-by-row, shift to the left of the matrix all columns having 1 in the first row.
Part # Machine #

5 1
1

4 1
1

2 1

# of 1s 3
2

3
6 4 1 5 2 # of 1s

1 1 1

1 1 1

2 2 1 1

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Chapter 3 - Flow, Space, and Activity Relationships

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4. Row-by-row, shift to the left of the matrix all columns having 1 in the first row.
Part # Machine #

5 1
1

4 1
1

2 1

# of 1s 3
2

3
6 4 1 5 2 # of 1s

1 1 1

1 1 1

2 2 1 1

Column-by-column, shift rows upward to form blocks of 1.

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5. Column-by-column, shift rows upward to form blocks of 1.

Part # Machine #

5 1
1

4 1
1

2 1

# of 1s 3
2

3
6 4 1 5 2 # of 1s

1 1 1

1 1 1

2 2 1 1

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Chapter 3 - Flow, Space, and Activity Relationships

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5. Column-by-column, shift rows upward to form blocks of 1.

Part # Machine #

5 1
1

4 1
1

2 1
1

# of 1s 3
2 1

3
6 5 4 1 2 # of 1s

1 1 2 2 2 2

1 1 1 3

2 2 1

Form cells.
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6. Form cells.
Cell 1
Part # Machine #

Cell 2
5 1
1

4 1
1

2 1
1

# of 1s 3
2 1

3
6 5 1

4
2 # of 1s 2 2 2

1
2

1
1 3

2
1

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Chapter 3 - Flow, Space, and Activity Relationships

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DCA: example - Bottlenecks

Part # 1 2 3 4 5 6 1 1 Machine # 1 1 1 1 1 1 1 1 1 1 2 3 1 4 5

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Chapter 3 - Flow, Space, and Activity Relationships

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DCA: example - Bottlenecks

Part # Machine #

5 1
1

4 1
1

2 1
1

# of 1s 3
2

3
6 5 4 1 2 # of 1s

1 1 1 1 1 1 3

2 2 2 1

Resulting table Cells?

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Part # 3 6 5

Machine #

5
1 1

4
1 1

2
1 1

Part # 3 6

Machine #

5
1 1

4
1 1

2
1 1

4
1 2 Part # 3 6 5 4 1 2
EIN4364

1
1

1
1 1

4
1 2 Part # 3 6 Machine # 5 1 1 4 1 1 1 2 1

1
1

1
1 1

Machine # 5 1 1 4 1 1 1 1 1 1 1 1 1 2 1 3 1

5 4 1 2

1 1 1 1 1 1

Chapter 3 - Flow, Space, and Activity Relationships

DCA: example - Bottlenecks

17

Part # 3 6 5

Machine #

5
1 1

4
1 1

2
1 1

4
1 2 Part # 3 6 5 4 1 2
EIN4364

1
1

1
1 1

Machine # 5 1 1 4 1 1 1 1 1 1 1 1 1 2a 1 2b 3 1

Part # 3 6 5 4 1 2

Machine # 5 1 1 4 1 1 1 1 1 1 1 1 1 2 1 3a 3b 1

Chapter 3 - Flow, Space, and Activity Relationships

DCA: example - Bottlenecks

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Machine 2 or 3 are bottlenecks for the cell formations given in the previous slide. Duplicate the machines!

Part # 3 6 5

Machine #

5
1 1

4
1 1

2
1 1

4
1 2

1
1

1
1 1

Do you still want to duplicate the machines?

Place the bottleneck machine in between the cells in the layout

Cell 1
M 2

Work area

Cell 2

Cell 3
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DCA: example - Bottlenecks

Question: What if the machine fractions of both 2 and 3 are too small? e.g. F2 <1 & F3<1 (or if we dont have enough budget.)

Part # 3 6 5

Machine #

5
1 1

4
1 1

2
1 1

where Fik denotes fraction of machine i required for part k

4
1 2

1
1

1
1 1

How would you do machine-cell assignment (i.e. cell layout)?

# of machine 2 required: 1.4+2.3=3.7 4 Put 1 in Cell 1 Put 2 in Cell 2 Put 1 in Cell 3 Or put 2 in Cell 1 & 2 in Cell 2 (but close to each other) remove cell 3
EIN4364 Chapter 3 - Flow, Space, and Activity Relationships

Cell 11 Cell

Work area
Cell 3

Cell Cell 2 2

DCA: example - Bottlenecks

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Question: Assume F23=1.4 & F25= 2.3

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Chapter 3 - Flow, Space, and Activity Relationships

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Chapter 3 - Flow, Space, and Activity Relationships

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Chapter 3 - Flow, Space, and Activity Relationships

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