Process is the assembly or manufacturing activities from raw material until finish good product. The flow process will running on assembly line by work station. Each work station must have their own process. Process set up for each workstation must considered the volume forecast & total working hours per day.
Cycle time for each workstation need to determine before plan the assembly activities to ensure that our assembly line was balance. Balancing of cycle times is very important and usefull for process control set up.
Example : Determine cycle time for PRODUCT XXX
Production/day : 10
Total working hours/day : 8
Cycle time : 10 unit production/8 hours : 0.8 hr per unit production.
Each workstation activities must be set up with cycle time 0.8 hrs. Total process activities will be done for each workstation not more or less than 0.8 hrs. The finish good product will roll out from our assembly line for each 0.8hr period time. From here size of man power to produce product xxx can be decided.
Example : Determine size of man power for PRODUCT XXX
Total man hours : 10
Total man power : Total man hours/ cycle time : 10/0.8 : 12.5 man power
Man power requred to produce product xxx with capacity 10u/day : 13 person.
Cycle time must use as mesurement tool for process control set up.
Monday, May 7, 2007
ENGINEERING THE MANUFACTURING/ASSEMBLY LINE
Assembly line must be engineering base on design capacity to ensure that the actual operation not under or over forecast. Normal practise recommended to setting the design capacity 30% more than volume required. The 30 % reservation is to fullfill the sales requirement increase more than forecast.
Design capacity should be calculate from basic/estimate process time and manhours for total manufacturing or assembly process. The working hours per year must be determine early to support the calculation of production per day and production per month.
After production capacity was setting, reverse engineering need to apply in order to draw up the basic layout for assembly line. Basic assembly line layout should considered the :
1. Total assembly process flow.
2. Raw material breakdown level.
3. Cycle time for one unit production.
4. Equipment and tool related.
5. Jigs and fixtures related.
6. Processing material required.
7. Product profile data.
8. Logistic flow.
The operation space or dimension on basic layout must be inclusive the working area, passage way, raw material racking, tool position, machine allocation, utilities required such as air point for air tool, power point for machine, and others item related to operation process flow .
From basic layout, detail technical drawing need to prepared. The technical drawings should be in individual title/item such as air piping drawing, power point drawing, process flow drawing and others. All individual technical drawing must include the small detail items to ensure that actual assembly line construction will meet the requirement setting.
Basic layout and technical drawing must review and revise(if any) to get a excelent result of assembly line design.
Design capacity should be calculate from basic/estimate process time and manhours for total manufacturing or assembly process. The working hours per year must be determine early to support the calculation of production per day and production per month.
After production capacity was setting, reverse engineering need to apply in order to draw up the basic layout for assembly line. Basic assembly line layout should considered the :
1. Total assembly process flow.
2. Raw material breakdown level.
3. Cycle time for one unit production.
4. Equipment and tool related.
5. Jigs and fixtures related.
6. Processing material required.
7. Product profile data.
8. Logistic flow.
The operation space or dimension on basic layout must be inclusive the working area, passage way, raw material racking, tool position, machine allocation, utilities required such as air point for air tool, power point for machine, and others item related to operation process flow .
From basic layout, detail technical drawing need to prepared. The technical drawings should be in individual title/item such as air piping drawing, power point drawing, process flow drawing and others. All individual technical drawing must include the small detail items to ensure that actual assembly line construction will meet the requirement setting.
Basic layout and technical drawing must review and revise(if any) to get a excelent result of assembly line design.
ENGINEERING THE MANUFACTURING PLANT
Engineering the manufacturing plant or set up new plant is the main task for production preparation. It's consequently of good sales forecast of product and must be more profitibality compared with order finish good product from others party. For example , one organisation for cars business suppose to developt manufacturing plant IF ordering the knock down (KD) more profitibality compared with ordering complete built unit (CBU) in total operation required and sales forecast in increasing position with long term period time.
After organisation decided to devolope and manage new manufacturing plant, all consideration items need to engineering for small details due to the design set up will impact to cost of investment, operation, maintenance and improvement for the future. The basic plant design will contribute to profit or loss to organisations.
The basic plant design must be well funtion for total production operation, safety to staff and environment, minimum cost for total operation and maintenance, also need to considered the future expenditure and improvement.
The raw ideas to engineering the new plant is the operation flow process and production capacity required. From here the organisation need to determine the :
1. Size of manufacturing plant.
2. Size of each building required for main operation and support.
3. Equipment and utilities.
4. Set up of total logistic flow and process flow.
5. Size of man power for total operation.
All the items mentioned will ensure that the organisation will have the RETURN OF INVESTMENT and gain the PROFIT after break event or certain period time.
After organisation decided to devolope and manage new manufacturing plant, all consideration items need to engineering for small details due to the design set up will impact to cost of investment, operation, maintenance and improvement for the future. The basic plant design will contribute to profit or loss to organisations.
The basic plant design must be well funtion for total production operation, safety to staff and environment, minimum cost for total operation and maintenance, also need to considered the future expenditure and improvement.
The raw ideas to engineering the new plant is the operation flow process and production capacity required. From here the organisation need to determine the :
1. Size of manufacturing plant.
2. Size of each building required for main operation and support.
3. Equipment and utilities.
4. Set up of total logistic flow and process flow.
5. Size of man power for total operation.
All the items mentioned will ensure that the organisation will have the RETURN OF INVESTMENT and gain the PROFIT after break event or certain period time.
Subscribe to:
Posts (Atom)