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IEM 5303 Advanced Manufacturing Systems Design 2000 John W. Nazemetz Slide 1 Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion Questions from Discussion Leaders Other Questions from Students Let’s Begin …

Slide 1 IEM 5303 Advanced Manufacturing Systems Design 2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

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Page 1: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 1

Welcome to Week 10 Discussion

Agenda for Tonight:

Review of Exam

Discussion Questions from Discussion Leaders

Other Questions from Students

Let’s Begin …

Page 2: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 2

Question 1 --

1. (25 pts.) Do CIM systems that employ Generative Computer Aided Process Planning benefit from the simultaneous use of Group Technology concepts?

Yes/No

Exam Review (1a)

Page 3: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 3

Question 1 -- cont.

If so, how and/or under what conditions? (25 of 25 possible)

Similar shapes/designs -> similar routings

Operational Efficiencies (families, batching in families – recalculate families each period)

Reduction in part variation, increase volume of common parts

Reduction in tooling with reduction in parts variation, tooling cost with volume increase

Exam Review (1b)

Page 4: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 4

Question 1 -- cont.

If not, why not (20/25 max available).

Generative CAPP, re-determines routing each time based on technical and economic feasibility so no permanent families established/establishable

BUT -- GT makes designs similar, so algorithmically derived routings are similar and other benefits are derivable.

Exam Review (1c)

Page 5: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 5

Exam Review (2)

Question 2 --(25 pts.) Define and explain Quality Function Deployment. List

and discuss its weak points. Define and Explain (15 pts.)

Process to document and assess products with respect to an ordered and weighted set of customer requirements, technical specifications, the correlation of customer requirements and technical specifications, comparison to competitors, required quality (tolerances) of part, production methods.

Weaknesses (10 pts.)Ability to gather customer

requirements/competitor dataAbility to translate requirements to specificationsAbility to define correct weights/economicsCan make week analysis “look” stronger than it is

Page 6: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 6

Exam Review (3)

Question 3 --

Consider the various models proposed in the text and in lecture for developing part families and manufacturing cell groupings. List, briefly define, and evaluate three (3) models/methods for cell and/or family formation (i.e., explain the philosophy/objective of each algorithm/procedure, the steps of each algorithm/procedure, and discuss its strengths and shortcomings). (8 pts each plus 1)

Machine Component Group Analysis

Production Flow Analysis

Rank Order Clustering (King)

GT Coding and Pattern Recognition

Single-Linkage Cluster Analysis - Similarity Coefficients

Page 7: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 7

Exam Review (4a)

Question 4a --

(17 pts.) Consider Robots and Numerical Control Machines. Explain the similarities and differences between the two.

Similarities Same basic technology, sensors

Similar programming

Similar function (move parts or tools in space)

Similar concepts – open/closed loop, pt to pt, continuous path, multi-axis, multiple tools/parts

DifferencesRobots less precise, accumulate error while NC

more precise, axis error is independent

Robot generally used for ergonomic and economic reasons, NC generally used for technological reasons

Page 8: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 8

Exam Review (4b)

Question 4 --

(8 pts.) Consider Robots and Numerical Control Machines. Briefly explain the role/use of each in FMS/Cellular Manufacturing under conditions of a) high product (design/shape) variability and low part volume (sales) as well as b) high part volume (sales) and low product (design/shape) variability.

Role – high product variability/low volumeRobot – allows flexibility via general purpose hand,

teach or low-cost/time programming

NC – allows precision manufacturing via reprogramming

Role – low product variability/high volumeRobot – allows labor replacement, repetitive

motions

NC – provides an alternative to custom, single purpose equip.

Page 9: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 9

Exam Review (5a)

Question 5 --

(25 pts.) Briefly define the life cycle and product concepts of Chris Vaughan. (15 pts.)

Life Cycle Concepts:

Design, Produce, Operate, Service, Dispose

All products have this life cycle

Iterative process (Less -> More detailed)

Applies across Supply Chain (all Levels)

Product Concepts:

Almost everything is a product

Products interact (Operate facility (product of “design and produce facility” is produces product

Page 10: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 10

Exam Review (5b)

Question 5 --

(25 pts.) Briefly define the life cycle and product concepts of Chris Vaughan. Comprehensively discuss how his definition/concepts apply/do not apply in the practice of Concurrent Engineering. (10 pts.)

Phases of life cycle define major inputs to concurrent engineering (design must consider production, operation, service and disposal of product)

Iteration of design Design document(s) (product) –

output/input of design facility, iterates from conceptual design to “final” design to redesign to re-redesign, …

Stages of design correspond to (design) supply chain

Page 11: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 11

Discussion Questions (Jeff Short)

Page 12: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 12

Discussion Questions (Jeff Short)

What is the difference between JIT, MRP, and Lean Manufacturing?JIT – minimum (zero) inventory goal

Absorbs fluctuations/disruptions via excess capacity (labor and machines)

MRP – maximize utilizationAbsorbs fluctuation by planning/scheduling

Lean Manufacturing – a manufacturing philosophy of efficiency which, when implemented, shortens the time between customer order and factory shipment by eliminating waste. "Uses less of everything compared with mass production”

Focus on efficiency/productivity of process

Page 13: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 13

Discussion Questions (Jeff Short)

Chapter 10 is about MRP and Chapter 11 is concerned with JIT. These seem to be diametrically opposed views of production planning and control. What is the current state of research to resolve the philosophical disagreements and reach a more practical operating philosophy?

Diametrically opposed in theoretically pure form –In practice, they blend –

Balance ability to predict and preplan fluctuating vs. constant stable system (production, customer, …)

No smooth/known demands (Seasonality, competitors)

No smooth production (machine/managerial breakdown)

No 100% availability (temporary demand exceeding capacity, rush orders)

Inventory to deal with unexpectedResearch using each method criteria (utilization/inventory)

Page 14: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 14

Discussion Questions (Jeff Short)

Can JIT exist in practice for a manufacturer with high variance in demand?

Yes, but if variance in demand is high, a large amount of excess production capability must be available to meet demand (on-time). As this cascades through a system, more interchangeable, cross trained workers needed with resultant higher labor costs.

Page 15: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 15

Discussion Questions (Jeff Short)

I understood the Wagner and Whitin Algorithm produced this property: either the inventory carried to period t+1 from period t must be zero or the production quantity in period t+1 is zero.

Question 6 asks the student to begin with an inventory, obviously a violation of the W-W algorithm. I felt there were several ways to deal with this problem, all of which modified the algorithm. Which way would you suggest?Reduce demand in first period(s) to reduce inventory to

zero.Is there a stochastic or fuzzy representation of the W-W

algorithm??Yes, simulation/modified Newsboy problem

“goodness of solution” is determined by ability to predict period demands/distribution of demand.

Page 16: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 16

Discussion Questions (Jeff Short)

Both W-W and Naidu & Singh treat the variable of h, holding costs, as a well-know entity. I have never worked for/with a company that could fix the value of h for any product under all storage conditions. How is h handled in your experience?

Via “Best Estimate” UsageV = value of part/product ($)

h = V x (interest rate +inflation rate + insurance rate + spoilage rate + pilferage rate + management rate)

+ Size x (cost of space)

All rates in ($/$inv), Cost of Space in $/unit volume

Can stratify inventory (Pareto-type Analysis)

Page 17: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 17

Discussion Questions (Mike Blanton)

Page 18: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 18

Discussion Questions (Mike Blanton)

Problem 10.7 was difficult to do. It followed example 10.4 which was continued from example 10.3. The examples seemed to leave information out, under the assumption that they were easy to follow. For me and I assume other students this was not the case. Could you please fill in the blanks.I’ll try on the next slides.

Page 19: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 19

Discussion Questions (Mike Blanton)

In example/problem, an LP model is solved.

For 10.7 –

One must first calculate the demand (dt)In period one dt = 50 + 60 + 70 + 80 = 260

units

In common units Xt = 2(50+70) + (60+80) =

380 hours

This will mean k = 1 hour/unit for 380 units

Perform similar calculations for other periods.

Then set up LP problem:

tfthtstitutotwtx FcHcIcIcUcOcWcXcMin

Page 20: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 20

Discussion Questions (Mike Blanton)

Subject to

With Wo=240, k=1

d1=380

All 0 subscripts dropped

Non-negativity

tttttttt FHIIUOWXMin 40245005604024120

tttt

tttt

tttttt

WkXUO

FHWW

IIIIXd

1

11

Page 21: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 21

Discussion Questions (Class)

Page 22: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 22

Discussion Questions (Class)

Other Questions as raised

Page 23: Slide 1 IEM 5303 Advanced Manufacturing Systems Design  2000 John W. Nazemetz Welcome to Week 10 Discussion Agenda for Tonight: Review of Exam Discussion

IEM 5303Advanced

Manufacturing Systems Design

2000 John W. Nazemetz

Slide 23

Discussion Session 10

End of Class

Have a Good Week and I’ll see you next time!