[精选]工艺选择与设施布置概述.pptx

工艺选择与设施布置Process Selection and Facility Layout 博士博士浙江大学浙江大学Dr.Weihua ZhouZhejiang University提纲 Outline工艺选择工艺选择Process selection:工艺类型 Process Type产品工艺矩阵 Production-Process Matrix 设施布置设施布置Facility layout:布置的类型Layout types产品原则布置：生产线平衡Product layout:Line-balancing problems工艺原则布置：各部门间的工作流量Process layout:Interdepartmental Work Flows工艺原则布置：系统规划设计Process layout:Systematic Layout Planning效劳布置Service Layout2023/4/182简介 Introduction工艺工艺Process一个组织将输入品转化为输出品的过程中的任何一个环节。注意和流程的区别工艺选择工艺选择Process selection组织产品生产或效劳提供的方式Deciding on the way production of goods or services will be organized主要根据主要根据Major implications劳动密集度Capacity planning设施布置Layout of facilities设备Equipment作业系统的设计Design of work systems2023/4/183工艺选择 Process Selection品种品种Variety系统需要处理多少品种的产品/效劳？How much灵活性灵活性Flexibility需要具有什么样柔性的设备？What degree产量产量Volume 期望的产量是多少？Expected output2023/4/184工艺类型 Process Types工艺专业化生产工艺专业化生产Job shop小规模Small scale批量生产批量生产Batch中等规模Moderate volume装配线生产装配线生产Repetitive/assembly line标准化程度较高的产品/效劳High volumes of standardized goods or services连续流程连续流程 Continuous生产高度标准化的产品/效劳Very high volumes of non-discrete goods2023/4/185工艺专业化生产Job shop2023/4/186一个中西医结合的医院医生会诊过程，设计心导管检查术A job shop process:A midwestern hospital medical team performs a diagnostic procedure involving a cardiac catheterization.批量生产Batch2023/4/187食物准备，一次一个菜单项，在 内华达州拉斯维加斯的凯撒宫的Spago厨房。A batch process:Food is prepared,one menu item at a time,in the kitchen of the Spago Restaurant in the Forum at Caesars Palace,Las Vegas,Nevada.装配线生产Repetitive/assembly line2023/4/188位于巴勒斯坦伊斯顿的宾尼和史密斯克雷奥拉产品制造商每年生产近30亿支蜡笔。A repetitive process:Binney&Smith,maker of Crayola products,produces nearly 3 billion crayons each year in its Easton,PA,manufacturing facility.连续流程 Continuous2023/4/189一个炼油厂的持续生产过程，把原油分解为石油，化工原油，以及其他产品。A continuous process:An oil refinery performs a continuous process,breaking down crude oil into petroleum,chemicals,and many other products.2023/4/1810提纲 Outline工艺选择工艺选择Process selection:工艺类型 Process Type产品工艺矩阵 Production-Process Matrix 设施布置设施布置Facility layout:布置的类型Layout types产品原则布置：生产线平衡Product layout:Line-balancing problems工艺原则布置：各部门间的工作流量Process layout:Interdepartmental Work Flows工艺原则布置：系统规划设计Process layout:Systematic Layout Planning效劳布置Service Layout产品-工艺矩阵Product Process MatrixDimension工艺专业化生产Job Shop批量生产Batch装配线生产Repetitive连续流程 Continuous工作变化工作变化Job variety很高Very High一般Moderate较低Low很低Very low生产灵活性生产灵活性Process flexibility很高Very High一般Moderate较低Low很低Very low单位成本单位成本Unit cost很高Very High一般Moderate较低Low很低Very low产量产量Volume of output很低Very Low较低Low较高High很高Very high2023/4/1811产品工艺矩阵Production-Process Matrix2023/4/1812产品结构、产品生命周期产品结构、产品生命周期多品种多品种小产量小产量品种较多品种较多高产量高产量标准化标准化大量生产大量生产顾客化顾客化低产量低产量广告广告重型机器重型机器中型机器中型机器食品加工食品加工汽车装配汽车装配麦当劳麦当劳石油化工石油化工面粉加工面粉加工工艺专业化工艺专业化批量生产批量生产装配线生产装配线生产连续流程连续流程过程结构过程结构不可行不可行不可行不可行效率测量效率测量柔性柔性(高高)单件成本单件成本(高高)柔性柔性(低低)单件成本单件成本(低低2023/4/1813提纲 Outline工艺选择工艺选择Process selection:工艺类型 Process Type产品工艺矩阵 Production-Process Matrix 设施布置设施布置Facility layout:布置的类型Layout types产品原则布置：生产线平衡Product layout:Line-balancing problems工艺原则布置：各部门间的工作流量Process layout:Interdepartmental Work Flows工艺原则布置：系统规划设计Process layout:Systematic Layout Planning效劳布置Service Layout设备布置 Facilities Layout布置：对业务部门、工作中心和设备进行布置：对业务部门、工作中心和设备进行布局，以确保系统中工作流运行顺畅。布局，以确保系统中工作流运行顺畅。Layout:the configuration of departments,work centers,and equipment,with particular emphasis on movement of work customers or materials through the system产品原则布置Product layouts工艺原则布置Process layouts成组技术单元布置Group technology cellular layout定点布置Fixed-Position layout2023/4/1814设施布置的目标Objective of Layout Design有助于到达产品和效劳的质量水平有助于到达产品和效劳的质量水平Facilitate attainment of product or service quality有效利用空间和人力有效利用空间和人力Use workers and space efficiently防止出现瓶颈防止出现瓶颈Avoid bottlenecks搬运成本最低搬运成本最低Minimize unnecessary material handling costs消除工人或物料的不必要搬运消除工人或物料的不必要搬运Eliminate unnecessary movement of workers or materials缩短生产和顾客效劳时间缩短生产和顾客效劳时间Minimize production time or customer service time实现安全生产实现安全生产Design for safety2023/4/1815布置决策的重要性Importance of Layout Decisions投入大量资金和精力投入大量资金和精力Requires substantial investments of money and effort具有长期性具有长期性Involves long-term mitments对短期运营的费用和效率有很大影响对短期运营的费用和效率有很大影响Has significant impact on cost and efficiency of short-term operations2023/4/1816布置决策的必要性The Need for Layout Decisions2023/4/1817无效率运营Inefficient operations如：高成本、瓶颈For Example:High Cost Bottlenecks产品或服务设计上的改变Changes in the design of products or services推出新产品或服务The introduction of newproducts or services意外Accidents安全危害Safety hazards2023/4/1818环境或其他法律要求的改变Changes inenvironmentalor other legalrequirements产量或产品组合的改变Changes in volume ofoutput or mix ofproducts方法或设备的改变Changes in methodsand equipment情绪问题Morale problems布置决策的必要性The Need for Layout Decisions工艺与布置Process and Layout2023/4/18192023/4/1820提纲 Outline工艺选择工艺选择Process selection:工艺类型 Process Type产品工艺矩阵 Production-Process Matrix 设施布置设施布置Facility layout:布置的类型Layout types产品原则布置：生产线平衡Product layout:Line-balancing problems工艺原则布置：各部门间的工作流量Process layout:Interdepartmental Work Flows工艺原则布置：系统规划设计Process layout:Systematic Layout Planning效劳布置Service Layout基本布置方式 Basic Layout Types产品原则布置产品原则布置Product Layout使大量产品或顾客顺利且迅速通过系统Layout that uses standardized processing operations to achieve smooth,rapid,high-volume flow采用生产线工作站方法生产产品Linear arrangement of workstations to produce a specific product工艺原则布置工艺原则布置Process Layout用来加工或提供涉及许多工艺要求的产品或效劳。Layout that can handle varied processing requirements以完成相似活动的部门或其他职能组为特征Centers/machines grouped by process they perform固定位置布置固定位置布置Fixed Position Layout加工对象保持不动，工人、材料和设备按需要四处移动Layout in which the product or project remains stationary;workers,materials,and equipment are moved as needed用于产品无法移动的工程中Used in projects where the product cannot be moved2023/4/1821混合布置 Hybrid Layouts单元布置单元布置Group technology cellular layouts成组加工单元机group machines into machining cells柔性制造系统柔性制造系统Flexible manufacturing systems自动化加工和材料处理系统automated machining&material handling systems混合装配线Mixed-model assembly lines一条生产线上生产多种型号的产品produce variety of models on one line2023/4/1822产品原则布置 Product Layout2023/4/1823原材料或顾客原材料或顾客Raw materialsor customer产成品产成品Finished item工作工作中心中心1工作工作中心中心1工作工作中心中心1材料材料/劳动力劳动力Material and/or labor工作工作中心中心1用于高重复性的生产流程用于高重复性的生产流程Used for Repetitive or Continuous Processing材料材料/劳动力劳动力Material and/or labor材料材料/劳动力劳动力Material and/or labor材料材料/劳动力劳动力Material and/or labor产品原则布置的优点Advantages of Product Layout产量高产量高High rate of output成本低成本低Low unit cost劳力专门化劳力专门化Labor specialization物料运输费低物料运输费低Low material handling cost工人和设备的利用率高工人和设备的利用率高High utilization of labor and equipment工艺路线选择及进程安排都在初步设计中确定工艺路线选择及进程安排都在初步设计中确定下来下来 Established routing and scheduling会计、采购程序化会计、采购程序化Routing accounting and purchasing2023/4/1824产品原则布置的缺点Disadvantages of Product Layout工作重复单调工作重复单调Creates dull,repetitive jobs技术低的工人可能对维持设备或产出质量缺乏兴趣技术低的工人可能对维持设备或产出质量缺乏兴趣Poorly skilled workers may not maintain equipment or quality of output对产量变化以及产品或工艺设计变化的适应性差对产量变化以及产品或工艺设计变化的适应性差Fairly inflexible to changes in volume设备故障对生产系统的影响很大设备故障对生产系统的影响很大Highly susceptible to shutdowns需要预防性维修能力需要预防性维修能力Needs preventive maintenance与个人产量相联系的鼓励方案是不可行的与个人产量相联系的鼓励方案是不可行的Individual incentive plans are impractical2023/4/1825U型生产线A U-Shaped Production Line2023/4/182612345678910开始开始In结束结束Out工人工人Workers工艺原则布置 Process Layout2023/4/1827Dept.ADept.BDept.DDept.CDept.FDept.E用于间断加工单件小批和成批过程用于间断加工单件小批和成批过程Used for Intermittent processing Job Shop or Batch Processes按功能制造过程布置Manufacturing Process Layout2023/4/1828LLLLLLLLLLMMMMDDDDDDDDGGGGGGPPAAAReceiving andShippingAssemblyPainting DepartmentLathe DepartmentMilling DepartmentDrilling DepartmentGrinding Department效劳过程布置 Service Process Layout女士内衣女士内衣WomensLingerie鞋子鞋子Shoes居家衣服居家衣服House-wares女裙女裙WomensDresses化装品及珠宝化装品及珠宝Cosmetics&Jewelry孩子区孩子区ChildrensDepartment女运动装女运动装WomensSportswear季节性季节性Entry&Seasonal男士区男士区MensDepartment2023/4/1829工艺原则的优点Advantages of Process Layouts满足多样的工艺要求满足多样的工艺要求Can handle a variety of processing requirements系统受个别设备出故障的影响不大系统受个别设备出故障的影响不大Not particularly vulnerable to equipment failures设备不会太昂贵设备不会太昂贵Equipment used is less costly可采用个人鼓励机制可采用个人鼓励机制Possible to use individual incentive plans2023/4/1830工艺原则的缺点Disadvantages of Process Layouts制品库存量较大制品库存量较大In-process inventory costs can be high要经常进行工艺路线选择及安排要经常进行工艺路线选择及安排Challenging routing and scheduling设备利用率低设备利用率低Equipment utilization rates are low物料运输慢、效率低物料运输慢、效率低Material handling slow and inefficient工艺复杂化使监督跨度减少工艺复杂化使监督跨度减少 plexities often reduce span of supervision对每一产品或顾客需求都特别关注对每一产品或顾客需求都特别关注Special attention for each product or customer会计、库存控制较复杂会计、库存控制较复杂Accounting and purchasing are more involved2023/4/1831固定位置布置Fixed Position Layouts混合布置混合布置Fixed Position Layout:加工对象保持固定，而工人、材料及设备需要加工对象保持固定，而工人、材料及设备需要转移转移Layout in which the product or project remains stationary,and workers,materials,and equipment are moved as needed.产品的性质决定了这种类型的布局Nature of the product dictates this type of layout质量Weight尺寸Size 批量Bulk大型建设工程大型建设工程Large construction projects2023/4/1832单元布置Cellular Layouts生产单元生产单元Cellular Production将工作分组，组的划分是有一系列相似零件所需要的运营决定Layout in which machines are grouped into a cell that can process items that have similar processing requirements成组技术成组技术Group Technology按相似工艺特征分组，保证生产效率The grouping into part families of items with similar design or manufacturing characteristics2023/4/1833比较 A parison2023/4/1834Group TechnologyMachine 1Machine 2Machine 3Machine 4Machine 5Materials inFinished goods out一个工人多台机器一个工人多台机器一个工人多台机器一个工人多台机器One Worker,Multiple MachinesOne Worker,Multiple Machines成组技术 Group Technology2023/4/1836Parts FamiliesGroup TechnologyDrillingDDDDGrindingGGGGGGMillingMMMMMMAssemblyAAAALathingReceiving and shipping LLLLLLLLGroup Technologya Jumbled flows in a job shop without GT cellsDrillingDDDDGrindingGGGGGGMillingMMMMMMAssemblyAAAALathingReceiving and shipping LLLLLLLLGroup Technologya Jumbled flows in a job shop without GT cellsDrillingDDDDGrindingGGGGGGMillingMMMMMMAssemblyAAAALathingReceiving and shipping LLLLLLLLGroup Technologya Jumbled flows in a job shop without GT cellsDrillingDDDDGrindingGGGGGGMillingMMMMMMAssemblyAAAALathingReceiving and shipping LLLLLLLLGroup Technologyb Line flows in a job shop with three GT cells Cell 3LMGGCell 1Cell 2Assembly areaAALMDLLMShippingDReceivingGGroup Technologyb Line flows in a job shop with three GT cells Cell 3LMGGCell 1Cell 2Assembly areaAALMDLLMShippingDReceivingGGroup Technologyb Line flows in a job shop with three GT cells Cell 3LMGGCell 1Cell 2Assembly areaAALMDLLMShippingDReceivingGGroup Technologyb Line flows in a job shop with three GT cells Cell 3LMGGCell 1Cell 2Assembly areaAALMDLLMShippingDReceivingG工艺原则布置与单元布置的比较Functional vs.Cellular Layouts方面方面Dimension工艺原则工艺原则Functional单元式单元式Cellular部门之间移动次数Number of moves between departments很多many很少few移动距离Travel distances较长longer较短shorter移动路线Travel paths变化variable固定fixed加工等待时间Job waiting times较长greater较短shorter加工时间Throughput time较长higher较短lower在制品数量Amount of work in process较大higher较小lower管理难度Supervision difficulty较大higher较小lower排程复杂性Scheduling plexity较大higher较小lower设备利用率Equipment utilization较低lower较高higher2023/4/18452023/4/1846提纲 Outline工艺选择工艺选择Process selection:工艺类型 Process Type产品工艺矩阵 Production-Process Matrix 设施布置设施布置Facility layout:布置的类型Layout types产品原则布置：生产线平衡Product layout:Line-balancing problems工艺原则布置：各部门间的工作流量Process layout:Interdepartmental Work Flows工艺原则布置：系统规划设计Process layout:Systematic Layout Planning效劳布置Service Layout产品布置：生产线平衡Design Product Layouts:Line Balancing2023/4/1847生产线平衡决定如何将作业分配到工作地，使分到各工作地的作业所需要的时间大致相等。Line Balancing is the process of assigning tasks to workstations in such a way that the workstations have approximately equal time requirements.流程或生产线平衡Line Balancing生产线平衡涉及把作业分配到工作地的决生产线平衡涉及把作业分配到工作地的决策。一般每个工作地只有一个工人来完成策。一般每个工作地只有一个工人来完成所有作业。所有作业。完全平衡的生产线，其线上的各活动完全完全平衡的生产线，其线上的各活动完全同步进行，能够实现工人和设备的最大利同步进行，能够实现工人和设备的最大利用。用。生产线平衡的目标，是在技术以及产量的生产线平衡的目标，是在技术以及产量的约束下，使生产线的闲置时间最少，效率约束下，使生产线的闲置时间最少，效率最高。最高。2023/4/1848Cycle Time节拍2023/4/1849节拍是指各工作地完成分配给它的作业所容许的最大时间。Cycle time is the maximum time allowed at each workstation to complete its set of tasks on a unit.产量 Determine Maximum Output2023/4/1850工作地数的理论最小值Determine the Minimum Number of Workstations Required2023/4/1851节拍和产量Example:Cycle time and Output tate2023/4/1852作业作业紧后作业紧后作业作业时间作业时间/分钟分钟ab0.2be0.2cd0.8df0.6ef0.3fg1.0gh0.4h-0.3Total3.8Example 2023/4/1853cdabefgh0.20.20.30.80.61.00.40.3OT=480 minutes/day,D=400/day,CT=1.2 minutes生产线平衡算法1.确定节拍，求出最少所需的工作地数确定节拍，求出最少所需的工作地数2.从工作地从工作地1开始，按顺序给工作地分配作业。作业的分配按作业先后开始，按顺序给工作地分配作业。作业的分配按作业先后顺序图由左至右进行。每个工作地的初始剩余时间为节拍。顺序图由左至右进行。每个工作地的初始剩余时间为节拍。3.在每一分配前，利用以下标准确定哪些作业够资格分配到一个工作在每一分配前，利用以下标准确定哪些作业够资格分配到一个工作地：地：A.该作业所有先行作业都已被分配B.该作业时间不超过该工作地的剩余时间4.如果没有够资格分配的作业，则开始下一个工作地的分配，转步骤如果没有够资格分配的作业，则开始下一个工作地的分配，转步骤3；如果出现多个够资格分配的作业，可采用以下方法进行分配：；如果出现多个够资格分配的作业，可采用以下方法进行分配：A.分配后续作业数最多的作业B.分配加工时间最长的作业如果还是一样，任意选择一个作业。5.每当一个作业分配后，计算该工作地的剩余时间。剩余时间等于原每当一个作业分配后，计算该工作地的剩余时间。剩余时间等于原有剩余时间减去当前分配作业的时间。有剩余时间减去当前分配作业的时间。6.继续步骤继续步骤35，直到所有作业分配完毕。，直到所有作业分配完毕。7.计算指标如闲置百分比、效率计算指标如闲置百分比、效率2023/4/1854生产线平衡原则Line Balancing Rules先分配后续作业数最多的作业先分配后续作业数最多的作业Assign tasks in order of most following tasks.根据位置权数分配任务根据位置权数分配任务Break the tie:assign tasks in order of greatest positional weight.2023/4/1855生产线平衡Process of Line Balancing2023/4/1856工作地工作地剩余时间剩余时间候选作业候选作业可行作业可行作业分配作业分配作业闲置时间闲置时间11.2a,ca,ca 0.21.0b,cb,cc 0.80.2b,dbb 0.20e,d-0.021.2e,de,dd 0.60.6eee 0.30.3f-0.331.2fff 1.00.2g-0.241.2ggg 0.40.8hhh 0.30.5-0.5Total1.0bdefgcah分配结果 Allocation Out e2023/4/1857Workstation 4(0.7)Workstation 3(1.0)Workstation 2(0.9)Workstation 1(1.2)bdefgcahWorkstation 4(0.7)Workstation 3(1.0)Workstation 2(1.1)Workstation 1(1.0)bdefgcah2023/4/1858瓶颈工作地 Bottleneck Workstation1 min.2 min.1 min.1 min.30/hr.30/hr.30/hr.30/hr.瓶颈工作地 Bottleneck平行工作地 Parallel Workstations2023/4/18591 min.2 min.1 min.1 min.60/hr.30/hr.30/hr.60/hr.2 min.30/hr.30/hr.平行工作地平行工作地Parallel Workstations效劳业的流程平衡分析活活动动描述描述时间时间秒秒1检查检查申申请书请书的正确性的正确性152处处理和理和记录记录收收费费303检查违规检查违规和限制情况和限制情况604眼睛眼睛测试测试405为为申申请请人拍照人拍照206颁发临时执颁发临时执照照302023/4/1860例：汽车驾照申请效劳的布局与流程例：汽车驾照申请效劳的布局与流程24015112030260603180404180205120306入口入口出口出口65551.412030260603180205120306入口入口出口出口6060365551.4入口入口2023/4/186111121111111112023/4/1862提纲 Outline工艺选择工艺选择Process selection:工艺类型 Process Type产品工艺矩阵 Production-Process Matrix 设施布置设施布置Facility layout:布置的类型Layout types产品原则布置：生产线平衡Product layout:Line-balancing problems工艺原则布置：各部门间的工作流量Process layout:Interdepartmental Work Flows工艺原则布置：系统规划设计Process layout:Systematic Layout Planning效劳布置Service Layout工艺布置设计Designing Process Layouts信息要求信息要求Information Requirements:一系列要安排的工作部门或工作中心List of departments个工作中心之间未来工作流的平面图Projection of work flows位置间的距离及单位距离物料运输费用Distance between locations投资于该布置的金额Amount of money to be invested一系列需特别考虑的事项List of special considerations现有建筑物内关键设施的位置、进出点以及载货处Location of key utilities2023/4/1863工艺布置：各部门间的工作流量Process Layout:Interdepartmental Flow信息信息Given各部门间实际的或预计的工作流量The flow number of moves to and from all departments各部门间运输成本费用The cost of moving from one department to another实际的或预计的布局The existing or planned physical layout of the plant决策决策Determine合理分布各部门，到达运费最少或距离最短的工艺专业化布置The“best locations for each department,where best means maxim