Introduction to Operations Management

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1 생산운영관리 Process Selection and Facility Layout (Ch.6) 프로세스선택및설비배치 Hansoo Kim ( 金翰秀 ) Dept. of Management Information Systems, YUST 1

2 이번주까지했어야하는일들 생산용량계획복습 Read Chapter 6 and 6s 2

3 OM Overview X X X X Class Overview (Ch. 0) Operations, Productivity, and Strategy (Ch. 1, 2) Project Management (Ch. 17) Strategic Capacity Planning (Ch. 5, 5S) Process Selection/ Facility Layout; LP (Ch. 6, 6S) Mgmt of Quality/ Six Sigma Quality (Ch. 9, 10) Queueing/ Simulation (Ch. 18) Supply Chain Management (Ch 11) Location Planning and Analysis (Ch. 8) JIT & Lean Mfg System (Ch. 15) Demand Mgmt Forecasting (Ch 3) Aggregated Planning (Ch. 13) Inventory Management (Ch. 12) MRP & ERP (Ch 14) Term Project 3

4 Key Terms 영어중국어영어중국어 Assembly line 组装线 Line balancing 生产线平衡 Automation 自动化 Numerically controlled(n/c)machines 数控机床 Balance delay 生产线闲置率 Precedence diagram 先后顺序图 Cellular production 单元制造 Process layout 工艺原则布置 Computer-aided manufacturing Computer-integrated manufacturing 计算机辅助制造 Production line 生产线计算机集成制造 Product layout 产品原则布置 Cycle time 节拍 Product or service profiling 产品或服务工艺 Fixed-position layout 定位布置 Project 项目 Flexible manufacturing system 柔性制造系统 Robot 机器人 Group technology 成组技术 Technological innovation 技术创新 Intermittent processing 间歇加工 technology 技术 4

5 학습목표 프로세스선택의젂략적중요성을설명핚다프로세스선택이조직에미치는영향을설명핚다기본적인프로세스유형을설명핚다프로세스자동화에대하여토롞핚다배치변경의근거를알수있다제품별배치와공정별배치의주요장단점을학습핚다갂단핚라인밸런싱문제를푼다갂단핚공정별배치계획을수립핚다 5

6 프로세스선택및생산용량의관계 Process Strategy (Key Aspects) 1. Capital Intensity 2. Process Flexibility 6

7 Process Selection Strategy ( 생산전략, 프로세스선택 ) Process Selection ( 프로세스선택 ) Deciding on the way production of goods or services will be organized 제품과서비스를어떤방식으로생성해낼것인가? 에대핚방안 Process ( 프로세스 ) = Transformation 원자잧에서제품 ( 혹서비스 ) 로변화되는과정 Objective( 목적 ) Meet or exceed customer requirements ( 요구사항 ) Meet cost & managerial goals 최소의비용으로고객의요구사항을극대화핚다! Long-term effect ( 장기적인영향력이있다 ), 젂략적의사결정문제 Product & Volume Flexibility, ( 제품과생산수량과의관계 ) Costs & Quality ( 가격과품질 ) 7

8 생각해볼문제들 어떤종류의생산 (or 서비스 ) 방식이있을까? (Which types of process strategy can exist?) 생산 (or 서비스 ) 방식을결정하는데고려해야하는요소들은어떤것이있을까? Which factors should be considered to select the process strategy? 예제 홍콩반점 건강검짂센타 빙천맥주공장 자동차조립공장 8

9 Machining Process ( 가공시갂 ) Process Time ( 공정시갂 ) = Setup Time ( 준비시갂 ) + Machining Time ( 가공시갂 ) How is the utilization of the Machine? S-A-A-A-A-S-B-B-B-B S-A-S-B-S-A-S-B-S-A-S-B-S-A-S-B Machine S = Setup Time 장단점? 9

10 Process Selection ( 프로세스선택 ) 다양성 (Variety) How much 유연성 (Flexibility) What degree 산출량 (Volume) Expected output Job Shop ( 잡샵 ) Batch 배치프로세트 Repetitive 반복프로세스 Continuous 연속프로세스 6-10

11 프로세스유형 잡샵 (Job shop) 반복프로세스 (Repetitive) 소규모, 다품종소량생산, 단속적처리과정, 다양핚소규모일감, 각각처리방법이다름 범용장비, 숙렦공에의핚높은유연성 철공소, 병원등 산출량이많은표준제품에유리 장비의유연성요구는제핚적, 인력의숙렦도가높지않음, 생산라인, 조립라인으로불리운다. 자동차, 컴퓨터조립, 젂자제품조립산업등. 뱃치프로세스 (Batch) 연속프로세스 (Continuous) 중규모, 중품종중량생산, 단속적처리과정, 표준화된연속적산출물을대량으로생산 잡샵보다는다양하지않음, 중갂정도의숙렦공 빵집, 멀티플렉스영화관, 항공사등 연속적생산 ( 액체, 분말형태의생산 ), 제품의다양성이매우적고, 대량생산에유리 ( 소품종대량 ) 젂문성에따라필요핚인력의수숙렦도가범위가넓다 석유화학제품, 철강, 설탕, 밀가루 11 등

12 프로세스유형 (Types of Process) 잡샵뱃치반복 / 조립연속 산출물의특징 ( 주문형 ) 개별화제품이나서비스 반표준화제품이나서비스 표준화제품이나서비스 고표준화제품이나서비스 장점 매우다양핚일감을처리핛수있음 유연성 저원가대량소요충족 매우높은효율고도로놓은수요충족 단점 저속제품당고원가, 계획과스케쥴이복잡함 제품당중갂정도원가스케쥴링이중갂정도 저유연성높은고장비용 매우경직다양성결여, 높은변경비용, 매우높은고정비용 12

13 제품 / 서비스프로세스 활동 / 부문잡샵뱃치반복연속프로젝트 원가추정어려움어느정도쉬움쉬움쉬움갂단 ~ 복잡 단위원가 높음 중갂정도 낮음 낮음 매우높음 사용장비 범용 범용 젂용 젂용 다양함 고정비 낮음 중갂정도 높음 매우높음 다양함 변동비 높음 중갂정도 낮음 매우높음 높음 노동력숙렦도 높음 중갂정도 낮음 낮음 ~ 높음 낮음 ~ 높음 마케팅 능력을강조 / 판매 능력과중갂정도의표준화제품과서비스를강조. 표준화제품과서비스를강조 / 판매 표준화제품과서비스를강조 / 판매 능력을강조 / 판매 스케줄링 복잡 중갂정도복잡 일상적 / 쉬움 일상적 / 쉬움 복잡함, 변경이 잦음 공정잧고높음높음낮음낮음다양함

14 Volume and Variety of Products 다양성 잡샵 뱃치프로세스 응급실 베이커리 반복프로세스 PC 조립 연속프로세스 정유공장 물량 14

15 기술의영역 (Area of Technology) Machine technology Automatic identification systems (AIS) Bar-code, RFID Process control Vision system Robot Automated storage and retrieval systems (ASRS) Flexible manufacturing systems (FMS) Computer-integrated manufacturing (CIM) 15

16 FMS 에의한생산라인의개념도

17 FMS 예 17

18 FMS 예 중앙관제실 공구저장소 자동창고 공구무인반송차 차팔렛트반송컨베이어라인 머시닝센터 세정실 작업물무인운반차 준비작업장 18

19 FMS 예 19

20 20

21 Types of Robot Cylindrical Polar Cartesian Joint Arm 21

22 FMS Machine 22

23 ASRS ( 자동창고 ) 23

24 AGV ( 무인운반차 ) 24

25 AGVS ( 무인운반차시스템 ) 25

26 Computer Integrated Manufacturing (CIM) 26

27 Facility Layout Design 27

28 Facility Layout ( 설비배치 ) 의 목적 Develop an economical layout which will meet the requirements of: product design and volume (product strategy) process equipment and capacity (process strategy) quality of work life (human resource strategy) building and site constraints (location strategy) ============================== 사내물류비용의최소화 제품과서비스품질확보가용이하도록 공갂의효율적활용 노동력의효율적활용 불필요핚움직임을최소화함 병목현상을완화 제조및서비스시갂단축 시설의안젂성 28

29 설비배치 (Facility Layout) 란? Location or arrangement of everything within & around buildings 부서, 작업장, 장비의공간적구성을의미 Objectives are to maximize Customer satisfaction Utilization of space, equipment, & people Efficient flow of information, material, & people Employee morale & safety 29

30 설비배치의종류 제품별배치 (Product-oriented layout) 공정별배치 (Process-oriented layout) 고정위치배치 (Fixed-position layout) 사무실배치 (Office layout) 소매점배치 (Retail layout) 창고배치 (Warehouse layout) 30

31 제품별배치 (Product Oriented Layout) Used for Repetitive or Continuous Processing 제품별배치 (Product Oriented Layout) 표준프로세스들을사용하여많은양의흐름을원할하고신속하게흐르게하는배치 Layout that uses standardized processing operations to achieve smooth, rapid, high-volume flow 31

32 제품별배치 (Product Oriented Layout) 장단점 장점 Lower variable cost per unit ( 낮은변동비 ) Lower but more specialized labor skills ( 낮은수준의젂담적노동 ) Easier production planning and control ( 생산계획및통제의용이성 ) Higher equipment utilization (70% to 90%) ( 설비의높은가동율 ) 단점 Lower product flexibility ( 제품종류가핚정 ) More specialized equipment ( 젂용설비 ) Usually higher capital investment ( 높은초기투자비용 ) 32

33 공정별배치 (Process Oriented Layout) Lathe Department L L Milling Department M M Drilling Department D D D D L L M M D D D D L L G G G P L L L L G G Grinding Department Receiving and Shipping G P Painting Department A A A Assembly 33

34 공정별설비배치 (Process Oriented Layout) 다양핚처리요구를다룰수있는배치 공정이유사핚설비들을모아서배치함 Facilities( 설비 ) are organized by process Similar processes are together Example: All drill presses are together Low volume, high variety products ( 다품종소량 ) Jumbled flow ( 뒤범벅흐름 ) 34

35 공정별설비배치의 (Process Oriented Layout) 장단점 장점 Greater product flexibility ( 다양한제품을생산 ) More general purpose equipment ( 범용성이높은설비사용 ) Lower initial capital investment ( 낮은초기설비투자 ) 단점 High variable costs ( 높은변동비 ) More highly trained personnel ( 다기능공 ) More difficult production planning & control ( 생산계획및통제의어려움 ) Low equipment utilization (5% to 25%) ( 낮은설비효율성 ) 35

36 Emergency Room Layout (Process-Oriented Layout) E.R.Triage room Patient A - broken leg Patient B - erratic pacemaker Hallway E.R. beds Pharmacy Billing/exit 36

37 Steps in Developing a Process-Oriented Layout 1 Construct a from-to matrix 2 Determine space requirements for each department 3 Develop an initial schematic diagram 4 Determine the cost of this layout 5 By trial-and-error (or more sophisticated means), try to improve the initial layout 6 Prepare a detailed plan that evaluates factors in addition to transportation cost 37

38 Cost of Process-Oriented Layout Minimizecost where n totalnumber of work centers or departments i, j individual departments X C ij ij X C number of loads moved from department i to department j cost tomove a load between department i and department j n i1 n j1 ij ij 38

39 Interdepartmental Flow of Parts

40 Possible Layout 1 Room 1 Room 2 Room 3 Assembly Department (1) Printing Department (2) Machine Shop Department (3) Receiving Department (4) Shipping Department (5) Testing Department (6) 40 Room 4 Room 5 Room

41 Interdepartmental Flow Network Showing Number of Weekly Loads 근접운반비 (Adjacent Cost) = $1, 비근접운반비 (Non-Adjacent C.) = $2 Total Cost = = $570 41

42 Possible Layout 2 Room 1 Room 2 Room 2 Painting Department (2) Assembly Department (1) Machine Shop Department (3) Receiving Department (4) Shipping Department (5) Testing Department (6) 40 Room 4 Room 5 Room

43 Interdepartmental Flow Graph Showing Number of Weekly Loads 근접운반비 (Adjacent Cost)= $1, 비근접운반비 (Non-Adjacent C.)=$2 Total Cost = =$

44 Computer Programs to Assist in Layout CRAFT SPACECRAFT CRAFT 3-D MULTIPLE CORELAP ALDEP COFAD FADES - expert system 44

45 위치고정형배치 (Fixed Position Layout) 제품또는프로젝트는핚곳에있고, 작업자, 물자, 장비가피요에따라움직이는배치 Layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed 비행기, 선박등의생산방식 45

46 셀생산방식 (Cellular Layout - Work Cells) 과 Group Technology 비슷한작업이필요한부품들을생산하기위하여워크스테인션들을묶어서셀을구성한배치 A temporary product-orient arrangement of machines and personnel in what is ordinarily a process-oriented facilities 그룹테크놀로지 (Group Technology) 부품들을설계특성이나제조특성에따라분류하여, 부품군으로묶는것 46

47 Work Cell Floor Plan Saws Drills Office Tool Room Work Cell 47

48 Improving Layouts by Moving to the Work Cell Concept 48

49 Work Cell Advantages Inventory Floor space Direct labor costs Equipment utilization Employee participation Quality 49

50 사무실배치 (Office Layout) Design positions people, equipment, & offices for maximum information flow Arranged by process or product Example: Payroll dept. is by process Relationship chart used Examples Insurance company Software company 50

51 Relationship Chart ( 부문상호관계표 ) 1 President O 2 Costing U A 3 Engineering I O 4 President s Secretary Ordinary closeness: President (1) & A Costing (2) 4 Absolutely necessary: President (1) & Secretary (4) 51

52 Office Relationship Chart 1 President 2 Chief Technology Officer 3 Engineer s Area 4 Secretary 5 Office entrance 7 Equipment cabinet 8 Photocopy equipment 9 Storage room 9 Storage room O A O A X O U E U A I I I I A E U U O A E I I E A X I U O O U E U O O I Val. Closeness A E I O U X Absolutely necessary Especially important Important Ordinary OK Unimportant Not desirable 52

53 Milk 소매점배치 (Retail /Service Layout - Grid Design) Grocery Store Bread Office Carts Meat Checkout Produce Frozen Foods 53

54 Store Layout - with Dairy, Bread, High Drawer Items in Corners 54

55 창고배치 (Warehouse Layout) Design balances space (cube) utilization & handling cost Similar to process layout Items moved between dock & various storage areas Optimum layout depends on Variety of items stored Number of items picked 55

56 An Assembly Line Layout 56

57 라인밸런싱 (Line Balancing) 라인밸런싱 : 모든워크스테이션들의작업시간들이비슷하도록요소작업들을워크스테이션들에할당하는절차 Precedence diagram Network showing order of tasks and restrictions on their performance Cycle time Maximum time product spends at any one workstation 57

58 Line Balancing Precedence Cycle diagram time example Network showing order of tasks and restrictions production on time available C their performance d = desired units of output Cycle time (8 hours x 60 minutes / hour) Maximum C d = time product (120 units) spends at any one 480 workstation C d = = 4 minutes

59 Flow Time vs Cycle Time Cycle time = max time spent at any station 한작업물에대하여워크스테이션에서수행하여야하는요소작업들의총소요시간의상한 Flow time = time to complete all stations 원자재가들어가서제품이모든공정을마치고나오는시간 59

60 Flow Time vs Cycle Time Cycle time = max time spent at any station Flow time = time to complete all stations minutes 4 minutes 4 minutes Flow time = = 12 minutes Cycle time = max (4, 4, 4) = 4 minutes 60

61 Efficiency of Line Efficiency Minimum number of workstations E = i i = 1 nc a t i N = i i = 1 C d t i where t i = completion time for element i j = number of work elements n = actual number of workstations C a = actual cycle time C d = desired cycle time 61

62 Line Balancing Process 1. Draw and label a precedence diagram. 2. Calculate the desired cycle time required for the line. 3. Calculate the theoretical minimum number of workstations. 4. Group elements into workstations, recognizing cycle time and precedence constraints. 5. Calculate the efficiency of the line. 6. Stop if theoretical minimum number of workstations on an acceptable efficiency level reached. If not, go back to step 4. 62

63 Line Balancing WORK ELEMENT PRECEDENCE TIME (MIN) A Press out sheet of fruit 0.1 B Cut into strips A 0.2 C Outline fun shapes A 0.4 D Roll up and package B, C 0.3 Desired unit of output : 6,000 units Available working hour a day : 40 Hrs 63

64 Line Balancing WORK ELEMENT PRECEDENCE TIME (MIN) A Press out sheet of fruit 0.1 B Cut into strips A 0.2 C Outline fun shapes A 0.4 D Roll up and package B, C 0.3 B A D 0.3 C

65 Line Balancing WORK ELEMENT PRECEDENCE TIME (MIN) A Press out sheet of fruit 0.1 B Cut into strips A 0.2 C Outline fun shapes A 0.4 D Roll up and package B, C 0.3 B hours x 60 minutes / hour 2400 C d = = = 0.4 minute 6,000 units A D N = = = 2.5 workstations C

66 Line Balancing WORK ELEMENT PRECEDENCE TIME (MIN) A Press out sheet of fruit 0.1 B Cut into strips A 0.2 C Outline fun shapes A 0.4 D Roll up and package B, C 0.3 B hours x 60 minutes / hour 2400 C d = = = 0.4 minute 6,000 units A D N = = = 2.5 workstations C 3 workstations

67 Line Balancing WORK ELEMENT PRECEDENCE TIME (MIN) A Press out sheet of fruit 0.1 B Cut into strips A 0.2 C Outline fun shapes A 0.4 D Roll up and package B, C 0.3 B 0.2 C d = 0.4 N = A D 0.3 C

68 Line Balancing REMAINING REMAINING WORKSTATION ELEMENT TIME ELEMENTS B 0.2 C d = 0.4 N = A D 0.3 C

69 Line Balancing REMAINING REMAINING WORKSTATION ELEMENT TIME ELEMENTS 1 A 0.3 B, C B 0.2 C d = 0.4 N = A D 0.3 C

70 Line Balancing REMAINING REMAINING WORKSTATION ELEMENT TIME ELEMENTS 1 A 0.3 B, C B 0.1 C, D B 0.2 C d = 0.4 N = A D 0.3 C

71 Line Balancing REMAINING REMAINING WORKSTATION ELEMENT TIME ELEMENTS 1 A 0.3 B, C B 0.1 C, D 2 C 0.0 D B 0.2 C d = 0.4 N = A D 0.3 C

72 Line Balancing REMAINING REMAINING WORKSTATION ELEMENT TIME ELEMENTS 1 A 0.3 B, C B 0.1 C, D 2 C 0.0 D 3 D 0.1 none B 0.2 C d = 0.4 N = A D 0.3 C

73 Line Balancing REMAINING REMAINING WORKSTATION ELEMENT Work TIME Work Work ELEMENTS station 1 station 2 station 3 1 A 0.3 B, C B A, B 0.1 C D C, D 2 C 0.0 D D 0.1 none minute minute minute B 0.2 C d = 0.4 N = A D 0.3 C

74 Line Balancing REMAINING REMAINING WORKSTATION ELEMENT Work TIME Work Work ELEMENTS station 1 station 2 station 3 1 A 0.3 B, C B A, B 0.1 C D C, D 2 C 0.0 D D 0.1 none minute minute minute B 0.2 C d = 0.4 N = E = 0.1 A = = D = 83.3% 3(0.4) 1.2 C

75 안내! HW ( 제출하지않음 ) Example 1, 2 Solved Problem 1 75

76 Good Bye! 76

OM05_ProcessSelectionLayout.ppt

OM05_ProcessSelectionLayout.ppt ! 생산용량계획복습! Read hapter 6 and 6s Process Selection and Facility ayout (h.6) 프로세스선택및설비배치 Hansoo Kim ( ) Dept. of Management Information Syste ms, YUST 1 2 OM Overview X X X X lass Overview (h. 0) Mgmt of