Lecture 5

Production Flow Analysis

1111111111222222222233333333334444
1234567890123456789012345678901234567890123
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

1
1

1
1

1
1
1
11 1 1
111

1
1
1 11
111

1
1 1 1
1
111 1 1 1
1
1
1 1
11
111 1 1
1
111 1 11 11
1
1
1
111
11 11
111 11 11 1 11 1 1
1 1
1
1
1
1
11 1 1
1
11
11
1
1
1
1
1
1 1 1
1
1 1 1 1
1
1
1
1
1
1
1
1
1 1
1
1 1
1
1
1
1
11
1

King and Nakornchai, 1982

Frequency table
Machines 1

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

0
6
5
7
13
17
3
18
8
7
6
5
2
4
7
5

0
6
5
7
13
17
3
16
8
7
4
4
0
4
7
5

0
6
5
7
13
15
0
15
8
4
4
4
0
4
7
5

0
6
5
7
13
13
0
13
8
0
4
4
0
4
7
5

0
6
5
6
12
13
0
10
8
0
0
2
0
4
7
5

0
6
5
6
12
13
0
9
8
0
0
0
0
4
7
5

2
8
5
7
13
19
3
19
10
7
6
5
2
4
7
7

Module 1 - Machine 1 as nucleus

Machines

37 42

16

*
4

Module 2 - Machine 13 as nucleus

Machines

3 24

13

* *

* *

11

* *

12

*
5

Modules for the given matrix

Modules

Machines

Components

1 2 6 8 9 16

37 42

13 8 11 12

3 24

7 6 8 10

1 13 25

10 6 8

12 26 31 39

11 4 5 8 12

9 20 27 30

12 8

11 22

14 2 6 8 9 16 3

2 6 17 35

3 6 16

7 34 36

16 2 9 6 8

10 8 32 38

10

2896

28 40

11

12

4 5 15 6 8

5 14 19 21 23 29

13

6 5 8 15

8 33 43

14

15 5 8

41

15

85

15

16

16
6

Modules after merger

Module

Machines

Components

1 2 6 8 9 16

4 28 40 10 18 32 38 37 42

8 11 13 12

11 22 3 24

6 7 8 10

12 26 31 39 1 13 25

4 5 8 11 12

9 20 27 30

2 6 8 9 14 16 3

7 34 36 2 6 17 35

4 5 15 6 8

16 15 41 8 33 43 5 14 19 21 23 29
7

7 34 36 2 6
2
*
6 * *
* *
8
*
9
*
14 *
* *
16
*
3 * * *

17 35
*

Remove
component 2
Component 2 goes to machine
cell (1,2,6,8,9,16). Intercell move 2-14

Components
6, 7, 17, 34, 35
and 36 need
machines
3, 6, 14
We save 4
machines
8

4
5
8
11
12

9 20 27 30
*
*
* * *
* * * *
* *

Remove
component 9
Components 20, 27, 30 go to
machine cell (8,11, 12, 13).

Component
9 goes to machine
cell (4,5,6, 8,15)
Component 9
visits machine 11
in cell (8, 11, 12, 13)
We eliminate this cell!
And create 1 intercell
move
9

Modules after synthesis

Module Machines

Components

1 2 6 8 9 16 2 4 10 18 28 32 37 38 40 42

8 11 12 13

3 11 20 22 24 27 30

6 7 8 10

1 12 13 25 26 31 39

3 6 14

6 7 17 34 35 36

4 5 6 8 15

5 8 9 14 15 16 19 21 23 29
33 41 43
10

Final block diagonal structure

11233344 1333
1111222344 112233 122223
2408827802677456589456913931312356193102470
1
2
9
16
3
14
4
5
6
8
15
7
10
11
12
13

1 1
1 1 111111
111111111
1 11 111 1
1

1
1

11111
1 1 1

11 111111
1 11

1 11 11111
1111111111111
1 11 1 1 1 111
1
111 1 111 111
1 111 11
1 1 11 111
111
111111
1
1 1 111
1 1111
1
1

Intercell move after duplicating 6 and 8

11

Final Solution

5 cells
Machines 6 and 8 - 4 each required
2 intercell moves

Capacity Planning
Cell Layout
Processing times
Set up times
Volumes
Number of machines available

12

Lecture 6

Capacity Planning
Layout
Exercise on PFA
Reducing Intercell moves

13

Final block diagonal structure

11233344 1333
1111222344 112233 122223
2408827802677456589456913931312356193102470
1
2
9
16
3
14
4
5
6
8
15
7
10
11
12
13

1 1
1 1 111111
111111111
1 11 111 1
1

1
1

11111
1 1 1

11 111111
1 11

1 11 11111
1111111111111
1 11 1 1 1 111
1
111 1 111 111
1 111 11
1 1 11 111
111
111111
1
1 1 111
1 1111
1
1

Intercell move after duplicating 6 and 8

14

Let the volume of part j per year = dj. Let the unit
processing time for part j on machine i is pij. The time
required on machine i per year for part j = pijdj

Let the time available on machine i per year = Ai. If the

organization works 6 days a week for 16 hours a day,
the time available per year is 4992 hours. Ai = k times
4992 where can be 70 to 80% and includes set up times
and other non available times.
The number of type I machines required to make the
volume of part j is given by
p d

aij

is a fraction. Usually, 0 aij 1

ij

Ai
15

Unidirectional flow
1
1

5
6

3
2
1

3
3

1
2

16

2 cells
Group
No.
1

Machines

Parts

3, 1, 4, 5, 6

1, 4, 5, 6

2, 5, 6

2, 3, 7, 8

17

5
6

3
4

P5
P4
P1

P2, P3, P7

P6

Cell 1
Extra machines

Cell 2

P8

Lecture 7

Exercise on PFA
Reducing Intercell moves
Rank Order Clustering

19

Exercise

A
B
C
D
E
F
G
H
I
J

1
10
30
20

3
8
20
20

4 5 6 7 8 9
18
15
30
16
19
30
40
10 20
20
15
20 20 15
10
20
30
20
10
15
10
20

10 11 12 13 14
10 20
15
25
30
20
25
20
15
20
15
10
20
20
15
15

15 16
20
20 25
20
10 20
15

17 18 19 20
15
30
20
40
30
20
30
20
15
20
20
20
10
15

UNU
TOTAL
TILIS
146
54
255
45
190
10
170
30
100
0
140 -40
60
40
90
10
50
50
60
40

No.
of
2
3
2
2
1
1
1
1
1
1

PRODUCTION FLOW ANALYSIS

1
1

D
E

1
1

1
1

1
1

9
1

1 1 1 1 1 1 1 1 1 2
0 1 2 3 4 5 6 7 8 9 0

1
1

1
1

1
1

1
1

Nucleus

PRODUCTION FLOW ANALYSIS

H
I
J
F

10

MODULE
-2:

MODUL
E1
Nucleus Machine "G"

Machine

Machin
es

10

MODULE
-3:
Machine

12

14

*
*

A
*

20

11

18

Nucleus Machine "I"

4

Nucleus Machine "H"

MODULE4:
Nucleus Machine "J"

Machine

7
*

MODULE6:

MODULE5:
Nucleus Machine "F"
Machine
A

13

15

Machine

16

*
MODULE-7:

D
E
F

Nucleus Machine "D"

*
*
*

Nucleus Machine "E"

Machine

17

19

Modules

Machines

Components

A, B, C, G

3, 5, 10, 12

A, B, C, D, F, H

6, 8, 11, 18

B, D, E, I, J

4, 9, 14, 20

D, E, F, J

2, 7

A, B, D, E, F

13, 15

A, B, C, D

16

A, B, C, E

1, 17, 19

Modules

Machines

Components

A, B, C, G

3, 5, 10, 12, 1, 17, 19

A, B, C, D, F, H

6, 8, 11, 18, 16

B, D, E, I, J

4, 9, 14, 20

D, E, F, J

2, 7

A, B, D, E, F

13, 15

Using interchangeability of machines

Modules

Machines

Components

A, B, C, G

3, 5, 10, 12, 1, 17, 19

A, B, C, D, F, H

6, 8, 11, 18, 16, 13, 15

B, D, E, I, J

4, 9, 14, 20, 2, 7

A, B, D, E, F

13, 15

F and I are interchangeable. Merge modules 3 and 4

C13 requires A, E, F and C15 requires B, D, F
C15 goes to module 2
C13 goes to module 2 with 1 IC move.
Remove module 5

Using interchangeability of machines

Modules

Machine Load

Components

A =91, B=110, C=151, G=105

3, 5, 10, 12, 1, 17, 19

A=55, B=85, C=39, D=60, F=105,

H=90

6, 8, 11, 18, 16, 13, 15

B = 60, D = 110, E=40, I=85, J=80

4, 9, 14, 20, 2, 7

Modules

Machine Load

Components

2A , 2B, 2C, 2G

3, 5, 10, 12, 1, 17, 19

A, B, C, D, 2F, 2H

6, 8, 11, 18, 16, 13, 15

B, 2D, E, I, J

4, 9, 14, 20, 2, 7

Avaliability = 85%

No. Machine Total

Load
1
A
146
2
B
255
3
C
190
4
D
170
5
E
100
6
F
140
7
G
60
8
H
90
9
I
50
10 J
80

Available Required
2
3
2
2
1
1
1
1
1
1

3
4
3
3
1 + 1 (IC)
2
2
2
1
1

8 new machines
Required. Cost = 160

E + G = 100 + 60 = 160
F + I = 140 + 50 = 190
H + J = 90 + 80 = 170
28

No.
1
2
3
4
5
6

Intercell moves
A to A
B to B
3 moves C to C
D to D
F to I
G to E

Loads after IC
71 + 75
80 + 85 + 90
91 + 99
90 + 80
90 + 100
85 + 75 (IC)

Required
2
3
2
2
1+1
1+1

Available
2
3
2
2
1+1
1+1

Utilization
90
99
90
100

8 IC moves; Cost = 4 lakhs

29

Another solution
MODULES

M/C

COMPONENTS

A,B,C,D,E,F,H

1,6,7,8,11,13,15,16,17,18,19

2
3

B,D,E,F,I,J
A,B,C,G

2,4,9,14,20
3,5,10,12

MODULES
1
2
3

M/C

COMPONENTS

2A,2B,2C,2D,E,F,H 1,6,7,8,11,13,15,16,17,18,19
B,D,E,F,I,J
A,B,C,G

2,4,9,14,20
3,5,10,12
30

No. Machine Total

Load
1
A
146
2
B
255
3
C
190
4
D
170
5
E
100
6
F
140
7
G
60
8
H
90
9
I
50
10 J
80

Available Required
2
3
2
2
1
1
1
1
1
1

3
4
3
3
2
2
1
2
1
1

7 new machines
Required. Cost = 140

E + G = 100 + 60 = 160
F + I = 140 + 50 = 190
H + J = 90 + 80 = 170
31

Another solution
MODULES

M/C

A,B,C,D,E,F,H

COMPONENTS
1,2, 4,
6,7,8,11,13,15,16,17,18,19

2
3

B,D,E,F,I,J
A,B,C,G

,9,14,20
3,5,10,12

No.
1
2
3
4
5
6

Intercell moves
A to A
B to B
C to C
D to D
F to I
E to E (2)

Loads after IC
90 + 81
180 + 90
89 + 76
90 + 80
90 + 100
100

Required
2
3
2
2
1+1
1

Available
2
3
2
2
1+1
1

Utilization

90
89
90
100

7 IC moves; Cost = 3.5 lakhs

32

Critical tradeoffs in cell design

Large cell size fewer extra machines

Extra machines Vs intercell moves
Reducing intercell moves
Cost vs utilization
Does PFA give the best solution?
Algorithmic version of PFA
Optimization (Minimize IC moves) (with and
without line analysis)
33