Formula Sheet: Plant Layout, PPC and Lean Manufacturing | Industrial Engineering - Mechanical Engineering PDF Download

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Industrial Engineering: Plant Layout, PPC &
Lean Manufacturing
1. Plant Layout
• Types of Plant Layout:
– Process Layout (Functional Layout)
– Product Layout (Line Layout)
– Fixed Position Layout
– Cellular Layout
• Objectives of Plant Layout:
min material handling cost, min movement, max space utilization
• Material Handling Cost (approx.):
Cost =
X
Material flow × Distance moved
2. Production Planning and Control (PPC)
• Types of Production Systems:
– Job Production
– Batch Production
– Mass Production
– Continuous Production
• Production Planning: Forecasting, routing, scheduling, loading.
• Production Control: Monitoring, adjusting, reporting.
• Scheduling:
Makespan = max(Completion time of all jobs)
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Page 2


Industrial Engineering: Plant Layout, PPC &
Lean Manufacturing
1. Plant Layout
• Types of Plant Layout:
– Process Layout (Functional Layout)
– Product Layout (Line Layout)
– Fixed Position Layout
– Cellular Layout
• Objectives of Plant Layout:
min material handling cost, min movement, max space utilization
• Material Handling Cost (approx.):
Cost =
X
Material flow × Distance moved
2. Production Planning and Control (PPC)
• Types of Production Systems:
– Job Production
– Batch Production
– Mass Production
– Continuous Production
• Production Planning: Forecasting, routing, scheduling, loading.
• Production Control: Monitoring, adjusting, reporting.
• Scheduling:
Makespan = max(Completion time of all jobs)
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• Gantt Chart: Visual representation of schedule showing start and finish times.
• Critical Ratio (CR):
CR =
Time remaining until due date
Processing time remaining
• Flow Time (T)
T = Waiting time+Processing time+Transport time
3. Lean Manufacturing
• Goal: Eliminate waste (muda) to improve efficiency and quality.
• Types of Waste:
TIMWOOD = Transportation, Inventory, Motion, Waiting, Overproduction, Overprocessing, Defects
• Just-In-Time (JIT):
Produce exactly what is needed, when needed, and in the amount needed
• Kanban: Visual scheduling system signaling when to produce or move items.
• 5S Methodology:
Sort, Set in order, Shine, Standardize, Sustain
• Total Productive Maintenance (TPM): Maximize equipment effectiveness by
proactive maintenance.
• Overall Equipment Effectiveness (OEE):
OEE = Availability× Performance Efficiency × Quality Rate
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