Assembly and Fabrication Plan—Plan and Building Plan—Basics of Line Layout—Layout Engineering—Executive Reading. Ease of Control in Line Manufacturing—Line Scheduling—Cycles—Production Line Control—Assembly Line Control—Executive Reading.
INTRODUCTION
Chapter XV, Flexibility. - A common misconception about line manufacturing is that it completely lacks flexibility. On the other hand, the progressive layout of work areas is what distinguishes line production.
ADVANTAGES AND LIMITATIONS
The result was that the short term did not cover the cost of the line installation. Total costs of the proposed production line for the desired volume will be prepared in the manner described.
PART II
Representatives of the production engineering group may work full-time or intermittently with the designers. Release of the design. - The fixing or "freezing" of the design follows any final adjustments to facilitate production.
I MINOR I__ UNITS
While both machines may sell for the same price, cutting costs. In line production, work study should be done along with tool design. As a rule, changes in the way the work is carried out compared to those prescribed in the operational list require the approval of the process engineer.
Track Movement.—If the movement of work on the track is an integral part of the equipment, the conveying device may still be the basis on which the line is built. In this case, it is wise to locate all processes where parts are handled in batches together, preferably at the beginning or end of the line. They also watch for overreach when the conveyor does not carry the work into the operator's normal work area.
When the work returns to the assembly line after the operation, the parts may or may not be replaced in the same position, depending on the speed and movement of the line. MATERIAL MOVEMENT 77 continuously, providing maximum automatic control and minimum line control. Once the units are soldered, operators return them to the far side of the assembly line.
LAYOUT
Line layout involves so many functions that it requires more coordination than any other activity in line production; because it affects all persons who are responsible for both the establishment and operation of the line. The location of the end of each line directly at the subsequent point of use is generally desirable when laying out any space for line production. This makes it necessary to work backwards from the point where the line ends and to adapt the production operations to the available space.
With the end of the line and the point of material receipt fixed, the overall flow within the plant can then be determined. Smaller parts can be stored and moved on-line periodically, where they are stored again until they are used. For the fabrication line, more storage space is allowed at the beginning of the line and between operations than at points along the line.
In the actual positioning of machines on a manufacturing line, the layout engineer works with information about how the machines will be loaded and unloaded; spaces that must be kept clean for servicing the car; and the location of the machine in relation to any foreseeable carrier. In assembly, people and small tools can be easily moved along the line and operations can be easily rearranged, combined, separated or simplified. This mobility of the actual site in which the operation is performed allows for freedom of appearance.
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In this case, the handlers have less freight traffic and are only processing inventory. the aisle that feeds and receives stock. Circular line. The so-called "circular line" can actually take almost any shape, as long as the ends are connected together, as in Figure 45. - The arrangement of the equipment at an odd angle in this machining of small parts. lines reduce material handling and increase the effectiveness of employee working time.
Flow in the factory. In the arrangement of the various lines so that they relate to the flow within the factory, the principle of maximum handling of the stock in its raw state influences the layout. If this is not feasible, the parts can be finished along a particular aisle and the raw material can be fed from the other end of the line or from another aisle. The position of the layout engineer in the organization is not fixed and he can operate in multiple departments.
It is widely recognized that good plant layout engineering is essential for the best arrangement of the equipment and the correct setup of the line. Layout Techniques.—The tools most commonly used in layout include some form of process sheet and a layout board. Size and Location of Banks.—The size of the part being manufactured limits the amount of float possible between operations.
B = — COT
Planning the balance.-The actual work of balancing usually begins with a list of the operations or various elements. When the line is adjusted by a powered conveyor, there is little problem in informing operators of the time they are allowed per cycle. 57.--The hands on the clock are set to indicate when the line will next move.
Conversely, if he and his workers cannot meet the 'set rate, a re-study of the line's operations and balance may be required. Balancing to meet line standard.—This example uses the line standard idea or line task. Select Time.—The actual minutes allowed for the part as shown on the time study observation sheet.
Line standard. - The line default or task set for the entire line as based on the slowest operation that will still allow the desired output. Number of changes and allowed time per shift.—The number of moves made per hour by the operator and the time spent moving when operators cover part-time or part-time operations. Money per surgery per hour. - The theoretical money earned by the line workers, that is, the class rate times the operator's working hours assigned to the operation.
INSTALLATION
STD.—Current production standard in hours per 100 pieces. 66.-This chart used in the analysis of existing or proposed line balance illustrates how. the job or workstation that consumes the most time automatically determines the standard production rate. Layout Record.—After a job is set up and installed, the layout engineer does a floor check of the line. Case II, Bottling and Packaging Line.-The production manager of a plant producing medicinal goods has the.
He calculated the length of the line by multiplying the number of operators (all on one side) by the space per operator and adding storage space. Functional Specialists.—The non-productive work of functional specialists may be so great that three or four men are employed servicing the line for each production operator. On this lower level of control depends much of the line's success.
As production and installation activities decrease and as operational control begins, some people involved in setting up the line may. 72.—This tool and follow-up record is used to plan the establishment of the line. Car manufacturing.-The introduction of new models or the resumption of seasonal activities is preceded by a seasonal forecast from management.
MATERIALS CONTROL
This means that material shipments from hundreds of vendors or subcontractors must be coordinated with the production schedules of the plants being served. To know the daily requirements of various items or components, the number of parts of each item in each complete assembly should be determined. The per-unit usage of each item multiplied by the daily production rate of complete units equals the item's daily requirements.
It is the function of the purchasing department to find vendors who can ensure the steady and reliable flow of the required material. In selecting vendors to supply line manufacturing plants, the integrity of the vendor and its ability to supply the right parts when they are required are as important as price. The seller is normally guaranteed a minimum quantity that will be purchased and informed of anticipated peak production.
In most cases, the follow-up clerks actually control the vendor's shipments by calculating the requirements and notifying the vendors of the desired delivery schedule. The work of the follow-up clerks in the control of incoming parts and materials usually takes the form of a constant checking of receipts against requirements. Whether follow-up is a function of the purchasing department or the planning department is not important.
EMU IIIIII
It is his responsibility to operate production by keeping enough material in the right place on the line. On the line itself, material handling will be under the control of the production supervisor or the operators themselves. Save on the line. Parts can be stored in different places on the production line itself.
During assembly, most of the material is stored at the various stations along the line. Sometimes all parts for one assembly are stored at the head of the line and placed in one container. Near the line.—Material is sometimes stored at the end of the line as a bank before testing, repairing, repairing, or packaging.
Generally, the bank is held at the end of the line only until enough parts accumulate to make an economical shipment to the customer or warehouse. Identification of Parts.—Storage of parts along the line requires that they be clearly identified. Off-Line Storage.—It is not always practical to store parts at the line.
PRODUCTION CONTROL
