Rezza Prayogi - Master Thesis

UNIVERSITÄT DUISBURG-ESSEN

Facilities Planning Using Digital Factory

Rezza Prayogi Master Thesis

This thesis is made as a requirement to complete a Master Study in Production and Logistics (Mechanical Engineering Department) at Universität Duisburg-Essen (Germany).

Facilities Planning using Digital Factory

Master Thesis

ACKNOWLEDGEMENT I want to say thank you to everyone listed bellow, who gives a big impact in my life to continue finishing this master thesis.        

To my God (Allah SWT), who always give me a power and a chance to do everything that’s impossible to do. To my dad (Ali Djured) and my mom (Fariha), who always give me a support in everything I need to finish this master thesis. To my uncle (Ir. Ismaun, MM), who always give me support to continue my study. To my beloved Rafika Amelia,SE, who always patient in waiting me finishing my master degree. To my Professor in Universität Duisburg-Essen (Prof.Dr.-Ing. Bernd Noche), who give me a chance and challenge to make this master thesis possible to finish. To my all my friends in Universität Duisburg-Essen (Martinus Susilo, Dony Meitia, Kurnia Saputra, Monfi Subiharto, and a lot more), who always give me a bright day every day in Germany. I also want to thanks to Prof. Dr.-Ing. P.Köhler and Prof. Dr.-Ing. Diethard Bergers that have been teaching us how to create a world class product using the best software and system that I have ever learn. To Dassault Systemes, who create a great software (Solidworks and Delmia) that’s make me possible to create this master thesis.

There are more list that should be added here, I’m sorry to not be included here because of this paper space restriction. I want to thank you to all of you who have helped me, and to you who read my master thesis

Duisburg, 13 February 2008

Rezza Prayogi Universität Duisburg-Essen (UDE) Institute for Product Engineering (IPE)

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ABOUT THE COMPANY In this Introduction, I give a brief description about Moryl Klebetecnik GmbH (as a source for my thesis data), SolidWorks, and Delmia QUEST.

1. Moryl Klebetechnik GmbH H. Moryl GmbH has 15 years experience with the development and production of Gluing application and Measuring Technology for the most different traders. Since beginning this year they are to be looked by the union of various specialists and by the construction of a competent distribution team in the position, the producing industry, directly and to supply. Therefore they save the detour about the retailers. They are continuously anxious to adapt developments and constructions to the newest technological state to contribute thus to the best possible success for customer production. By the connection compatibility to all market friends to manufacturers they support its customer to reduce its spare part costs to a minimum. They support of a producing, innovative and highly competitive partner with a being convincing complete program for a very good price achievement relation, from certified service about gluing application and measuring technology, they own control technology and ultrasonic technology up to servicing and repair of its customer systems. They produces the following products: Piston pumps systems, gearwheel pumps systems, barrel glaze devices, coating states, automatic granulate material sponsor, order control, piston pumps, automatic tubes, pneumatics hand guns, surfaces order heads, order heads, spray order heads, order modules, nozzles for spray orders, tank filters and sieves, Inline filters, heating cartridges, Thermostat, magnet valves, glue fittings and screw connections, ultrasonic systems.

H.Moryl GmbH Duderstädter Str. 13 D-40595 Düsseldorf Germany www.moryl-klebetechnik.com

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2. Solidworks (a part of Dassault Systemes Corporation) SolidWorks Office Premium is the complete 3D product design solution, providing your product design team with all the design engineering, data management, and communications tools that they need in one package. SolidWorks 3D mechanical design software, perform product design work more quickly and accurately. SolidWorks offers the most time-saving capabilities of any product design software available. SolidWorks comes with Design Communication Tools. These tools demonstrate more effectively how products look and perform with SolidWorks Office Professional design presentation tools:  eDrawings Professional-- Generate accurate representations of 2D and 3D models that anyone can view, mark up, and measure without having to purchase their own mark up tools.  SolidWorks Animator-- Create compelling AVI files from SolidWorks parts and assemblies.  Photoworks - Create photorealistic images.  3D Instant Website-- Create and publish live web pages with 3D interactive content. SolidWorks comes also with CAD Productivity Tools. We can reduce design steps with SolidWorks Office Professional CAD productivity tools:  SolidWorks Toolbox-- Automate assembly tasks with a library of standard parts.  FeatureWorks-- Simplify the reuse of 3D CAD data created in varied file formats.  SolidWorks Utilities-- Find differences between two versions of the same part quickly and easily.  SolidWorks Task Scheduler--Saves time by enabling you to schedule resource intensive tasks, such as batch printing, running of analyses, and updating of project files during periods when you will be away from your workstation.  SolidWorks Design Checker - A timesaving tool for ensuring compliance with your organization's design standards.  SolidWorks Routing enables you to quickly and easily design pipe, tube, and electrical routes in your product designs.  SolidWorks ScanTo3D enables designers to open scan data in SolidWorks and convert it into surface and solid models. SolidWorks comes with Design validation software, which called CosmosWorks. CosmosWorks specifically tailored for designers and engineers who are not specialists in design validation, CosmosWorks helps improve product quality by indicating how SolidWorks models will behave before they are built.

SOLIDWORKS CORP 300 Baker Avenue, Concorde, MA 01742 United States of America www.SolidWorks.com Rezza Prayogi

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3. Delmia (a part of Dassault Systemes Corp) DELMIA QUEST provides a single collaborative environment for industrial engineers, manufacturing engineers, and management to develop and prove out best manufacturing flow practices throughout the production design process. Improve designs, reduce risk and cost, and maximize efficiency digitally, before spending money on the actual facility, to get it right the first time. By using QUEST to experiment with parameters such as facility layout, resource allocation, kaizen practices, and alternate scheduling scenarios, integrated product teams can quantify the impact of their decisions on production throughput and cost DELMIA QUEST is a powerful simulation development and analysis tool for validating and visualizing the impact of process flow decisions made for meeting production requirements. Reduce risk by validating affordability measures, and minimizing problems and unplanned costs associated with facility startup. QUEST provides a complete solution, providing the tools necessary for both efficient process flow analysis and effective presentation of results to customers, managers, and other engineering disciplines. DELMIA QUEST allows you to quickly build a simulation model to the level of detail required, adding more detail as necessary to improve accuracy throughout the design process. Conceptualize your processes by populating the model with intelligent objects and prebuilt sub-models from your libraries. Once your proposal is accepted, carry the same model into the design process by integrating it with existing design tools such as 2D/3D CAD, Microsoft spreadsheet and planning software, and other types of simulation applications such as ergonomic workplace assessment. Use the QUEST model to document the lessons learned through the systems integration process, quantifying the impact of design decisions. As your facility springs to life in the digital world, the system’s behavior is emulated with real processing times, speeds, staffing levels, schedules, failure rates, and timing. This interactive digital environment allows accelerated “what if” analysis to be explored, for evaluating production scenarios, product mixes, and other alternatives. Results are efficiently communicated back to the product/process team for incorporating the best solutions. Finally, as the facility is built, use QUEST to author an Express model of your proprietary processes and integrate the simulation using QUEST Express™ with your MES, ERP, MRP, PLC, or scheduling systems for assisting in production floor analysis and systems monitoring. In each stage, analyzing and presenting QUEST results to decision makers is simple and effective.

DELMIA CORP 900 N. SQUIRREL RD., SUITE 100 AUBURN HILLS, MI 48326 www.delmia.com

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PREFACE

This Master Thesis is based on the ISE Regulation and Master Study Plan for Mechanical Engineering, that’s must be followed for each student in Universität DuisburgEssen. This Master Thesis is created using my knowledge and combination lecture from Universität Duisburg-Essen, those lecture are:          

Product Development (Produktentwicklung), Prof. Dr.-Ing. Diethard Bergers Computer Aided Calculation and Simulation Methode (Computergestützte Berechnungs- und Simulationsmethoden), Prof. Dr.-Ing. P.Köhler Simulation in Logistics I (Simulation in der Logistik I), Prof. Dr.-Ing. Bernd Noche Simulation in Logistics II (Simulation in der Logistik II), Prof. Dr.-Ing. Bernd Noche Logistics and Material Flow I (Logistik und Materialfluss I), Prof. Dr.-Ing. Bernd Noche Logistics and Material Flow II (Logistik und Materialfluss II), Prof. Dr.-Ing. Bernd Noche Information System in Logistics (Informationssysteme in der Logistik), Prof. Dr.-Ing. Bernd Noche Facilities Planning and System Engineering I (Anlageplanung und Systemtechnik I), Dr.rer.nat. Bachtaler Facilities Planning and System Engineering II (Anlageplanung und Systemtechnik II), Dr.rer.nat Bachtaler Industrial Engineering, Dr.rer.nat Bachtaler

This Master Thesis theme is to combine a theory and a practice in Facilities Planning using Digital Factory as a tool. In real world, people is still using manual method to conduct Facilities Planning, that’s why I want to prove it that using Digital Factory, people can learn, create, and take a result faster than using manual calculation. Digital Factory can make a Facilities Planner more understand about their Facilities, but it is only a tool, without a good knowledge it will become a dumb tool. So the person behind the Digital Factory is still a must needed component to create a great successful Facility.

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Table of Contents Acknowledgement ............................................................................................................................... I-2 About the company .............................................................................................................................. I-3 Preface .................................................................................................................................................. I-6 Table of Contents ................................................................................................................................. I-7 Chapter I. Introduction........................................................................................................................ 1-1 I.1. Facilities Planning ....................................................................................................................... 1-1 I.2. Digital Factory ............................................................................................................................ 1-3 Chapter II. Theory ................................................................................................................................ 2-1 II.1. Product Design .......................................................................................................................... 2-1 II.2. Process Design .......................................................................................................................... 2-2 II.3. Schedule Design ........................................................................................................................ 2-2 II.4. Facilities Design ......................................................................................................................... 2-3 II.5. Computer Simulation ................................................................................................................ 2-3 II.6. How to Conduct Successful Facilities Planning ........................................................................ 2-4 II.6.1. Design Product ................................................................................................................... 2-4 II.6.2. Takt Time and Scrap Rates Calculation .............................................................................. 2-6 II.6.2.1. Takt Time ................................................................................................................... 2-6 II.6.2.2. Scrap and Rework ...................................................................................................... 2-7 II.6.3. Process Design ................................................................................................................... 2-8 II.6.3.1. Fabrication ................................................................................................................. 2-8 II.6.3.1.1. Route Sheet .................................................................................................... 2-8 II.6.3.1.2. The Number of Machine Needed ................................................................... 2-9 II.6.3.2. Work Cell Load Chart ............................................................................................... 2-10 II.6.3.3. Assembly and Packout Process Analysis .................................................................. 2-11 II.6.3.3.1. The Assembly Chart ...................................................................................... 2-11 II.6.3.3.2. The Assembly Line Balancing ........................................................................ 2-11 II.6.3.3.3. Packout ......................................................................................................... 2-13 II.6.4. Equipment and Space Used ............................................................................................. 2-14 II.6.4.1. Workstation Design.................................................................................................. 2-14 II.6.4.2. Space Determination ............................................................................................... 2-15 II.6.5. Material Handling Equipment Used................................................................................. 2-16 II.6.5.1. Material Handling Definition ................................................................................... 2-16 Rezza Prayogi

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II.6.5.2. Goals of Material Handling ...................................................................................... 2-16 II.6.5.3. The 20 Principles of Material Handling .................................................................... 2-17 II.6.5.4. The Material Handling Problem Solving Procedure ................................................. 2-18 II.6.5.5. Material Handling Equipment .................................................................................. 2-19 II.6.5.5.1. Types of Material Handling Equipment ........................................................ 2-19 II.6.5.5.2. Bulk Material Handling ................................................................................. 2-20 II.6.5.5.3. Fork Lift Truck ............................................................................................... 2-20 II.6.6. Cost Calculation ............................................................................................................... 2-25 II.6.6.1. How Much Will Our Product Cost? .......................................................................... 2-25 II.6.6.2. Material Handling Cost ............................................................................................ 2-26 II.6.6.3. Cost Reduction Formula........................................................................................... 2-26 II.6.7. Tips ................................................................................................................................... 2-27 II.7. How to Build Digital Factory.................................................................................................... 2-27 II.7.1. Getting Started With Delmia Quest ................................................................................. 2-27 II.7.1.1. Introduction ............................................................................................................. 2-27 II.7.1.2. Starting Quest .......................................................................................................... 2-27 II.7.1.3. Configuration Files ................................................................................................... 2-30 II.7.1.4. The User Interface ................................................................................................... 2-31 II.7.1.5. Pull Down Menu (Context Button) .......................................................................... 2-32 II.7.1.6. World Control Button .............................................................................................. 2-33 II.7.1.7. Using the Mouse ...................................................................................................... 2-37 II.7.2. Step by Step to Build Delmia Simulation ......................................................................... 2-37 Chapter III. Project and Calculation .................................................................................................... 3-1 III.1. Introduction ............................................................................................................................. 3-1 III.2. Design of Gas Grill .................................................................................................................... 3-1 III.3. Takt Time and Scrap Rates Calculation .................................................................................... 3-4 III.4. Process Design ......................................................................................................................... 3-7 III.4.1. Cycle Time and Fraction Equipment ................................................................................. 3-7 III.4.2. Assembly Chart and Packaging Line................................................................................ 3-16 III.4.3. Flow Analysis Technique ................................................................................................. 3-22 III.4.4. Activity Relationship Analysis ......................................................................................... 3-40 III.5. Equipment and Space Used ................................................................................................... 3-50 III.6. Material Handling Equipment Used ....................................................................................... 3-57 III.7. Cost Calculation...................................................................................................................... 3-61 Rezza Prayogi

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Chapter IV. Building Digital Factory .................................................................................................... 4-1 IV.1. Delmia Quest ........................................................................................................................... 4-1 IV.2. Experiment............................................................................................................................... 4-1 IV.2.1. Single Machine.................................................................................................................. 4-1 IV.2.2. Three Assembly Machine ................................................................................................. 4-2 IV.2.3. Conveyor System .............................................................................................................. 4-4 IV.2.4. Power and Free System .................................................................................................... 4-5 IV.2.5. Labor, Shift, and Downtime .............................................................................................. 4-7 IV.2.6. Labor I ............................................................................................................................... 4-9 IV.2.7. Labor II ............................................................................................................................ 4-10 IV.2.8. Labor III ........................................................................................................................... 4-11 IV.2.9. Pallet ............................................................................................................................... 4-13 IV.3. Gas Grill Manufacturing Simulation....................................................................................... 4-14 IV.3.1. Axle Production .............................................................................................................. 4-14 IV.3.2. Tank Holder Production .................................................................................................. 4-15 IV.3.3. Bottom Support Production ........................................................................................... 4-20 IV.3.4. Top Support Production ................................................................................................. 4-24 IV.3.5. Control Panel Production ............................................................................................... 4-29 IV.3.6. Tube Plugs Production .................................................................................................... 4-33 IV.3.7. Legs Extensions Production ............................................................................................ 4-36 IV.3.8. Knob Production ............................................................................................................. 4-39 IV.3.9. Legs Production .............................................................................................................. 4-42 IV.3.10. Wood Slats Production ................................................................................................. 4-46 Chapter V. Conclusion ......................................................................................................................... 5-1 V.1. Advantages ............................................................................................................................... 5-1 V.2. Disadvantages ........................................................................................................................... 5-1 LYBRARY .............................................................................................................................................. L-1 APPENDIX ........................................................................................................................................... A-1 A.1. Appendix I – Delmia Quest Modeling Terms ............................................................................A-2 A.2. Appendix II – CAD Modeling Terms ........................................................................................A-16

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CHAPTER I INTRODUCTION I.1. Facilities Planning Facilities planning determine how an activity’s tangible fixed assets best support achieving the activity’s objective. For a manufacturing firm, facilities planning involve the determination of how the manufacturing facility best supports production. It is important to recognize that contemporary facilities planning considers the facility as a dynamic entity and that a key requirement to facilities plan is its adaptability, that is, that facility’s ability to become suitable for new use. In this regard as a facilities planner, the notion of continuous improvement must be an integral element of the facilities planning cycle. The continuous improvement facilities planning cycle shown in Figure I.1, details this concept. Whether we are involved in planning a new facility or planning to update an existing facility, the subject matter should be of considerable interest and benefit. As depicted in Figure I.2, it is convenient to divide a facility into its location and its design components. The location of the facility refers to its placement with respect to customer, suppliers, and other facilities with which it interfaces. Also, the location includes its placement and orientation on a specific plot of land. The design components of a facility consist of the facility systems, the layout, and the handling system. The facility systems consist of the structural systems, the atmospheric systems, the enclosure systems, the lighting/electrical/communication systems, the life safety systems, and furnishings within the building envelope; and the handling system consists of the mechanisms needed to satisfy the required facility interactions. The facility systems for a manufacturing facility may include the envelope (structure and enclosure elements), power, light, gas, heat, ventilation, air conditioning, water, and sewage needs. The layout consists of the production areas, production-related or support areas, and personnel areas within the building. The handling system consists of the materials, personnel, information, and equipment handling systems required to support production. Determining how the location of a facility supports meeting the facility’s objective is referred to as facilities location. The determination of how the design components of a facility support achieving the facility’s objectives is referred to as facilities design. Therefore, facilities planning may be subdivided into the subject of facilities location and facilities design. Facilities location addresses the macro issues whereas facilities design looks at the micro elements.

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Specify/update primary and related activities to accomplish objectives

Determine space requirement for all activities

Maintain and continuously improve

What’s the feasibility of incorporating the new operation or facility on existing site?

No

Determine facility location

Yes Develop alternative plans and evaluate

Select facilities plan

Implement plan

Figure I.1 Continuous improvement facilities planning cycle1 Facilities location

Facilities planning

Facilities systems design Facilities design

Layout design

Handling systems design

Figure I.1 Facilities planning hierarchy1 1

Facilities Planning, 2nd ed. Tompkins, White, Bozer, Frazelle, Tanchoco, Trevino. McGraw-Hill 1996.

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I.2. Digital Factory The digital factory defined (in Generic term) as a comprehensive network of digital models and methods among other things simulation and 3D-Visualization. Their purpose is the holistic planning, realization, controlling and current improving of all substantial factory processes and - resources in connection with the product On the one hand by the digital factory an image of the material factory is understood, in order the processes running off therein to visualize, simulates and thus better to understand to be able. On the other hand the digital factory than the whole of all coworkers, software tools and processes, who are necessary for the production of virtual and material production, is defined. Further must be separated between the tools and methods of the digital factory and the vision of virtual production and virtual logistics. Virtual production designates as constant, experimentable planning, evaluation and control of production processes and - lay close with the help of digital models. The term of virtual logistics describes the software-supported planning of logistic processes and structures. Effective range of the digital factory is the production planning phase within the product life cycle. During this phase the main operating cost blocks are specified. Their purpose is the holistic planning, realization, controlling and current improving of all substantial factory processes and - resources in connection with the product (e.g. Motor vehicle, airplane). With the digital factory the field of activity between the production development and the production control is closed. While for production development and production control different methods and systems on the free market are acquisition, production planning is only meagerly supported. Principal activities during the product life cycle for the elucidation of the emphasis range of the digital factory can bee seen in Figure 1.1 below.

Figure I.1 Focus of the digital factory is production planning2 2

Reinhard, G.; Grundwald, S.; Rick, F.: Virtuelle Produktion – Virtuelle Produkte im Rechner produzieren. In: VDI-Z, 141, (1999) 12, S. 26.

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The digital factory does not only consist of software. The digital factory must be seen in the total context of the enterprise and can into four levels of the digital factory be arranged in such a way:  Database  Integration platform  Tools  Organization and planning workflow A goal of the digital factory is it, proven methods, to standardize processes and operational funds in such a way that they can be used with another product or with the successor than planning components again. For this usually a revision of the existing processes and the organization is necessary. During the process reorganization should on the four directions of attack of the digital factory.  common data base for the reduction of redundant data  Standardization of processes, resources as well as operational funds  consistent clarification of task, authority and responsibility over the process chain into a trade-spreading integrating process as well as  Possibilities for automation are respected. Tasks of the digital factory are among other things:  Assumption of the product planning data,  Process time planning,  Planning of the production processes,  Planning of the operational funds (construction proposal, definition number), employment factor planning,  Layout planning of the work and the jobs,  Cost evaluation as well as  Security of the results of planning  Delivery of the planning data to the enterprise. Increase in value of the digital factory is not only that costs are lowered with the purchase by parts and plants, but offers also substantial advantages regarding maintenance, flexibility and reliability. Routine activities of planning are transferred to the software. All process-taken part of planning settles its tasks at the computer and by Workflows are interlaced. Fixed times the progress in the planning process is made measurable. That secures the availability of the desired data at the correct time, in correct detailing and in the correct context. All relevant planning data (product, process, resources) are only once seized by the ranges involved and administered by a data base. They are for each planner, in the future also for suppliers, outfitters and suppliers, always in the current form available. A nuclear goal is it to be able to use the data with new models very early to meet about in order for cost estimation.

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Figure I.2 Area of digital factory3 However does not have itself the digital factory was located today (in the middle of 2007) surface covering in the producing industry as planning system interspersed. So far only large-scale enterprises trust in the new technology. Reasons for this are because of to high costs and the unclear use. Further it lacks in the operational daily business within many ranges the necessary user acceptance.

3

Reinhard, G.; Grundwald, S.; Rick, F.: Virtuelle Produktion – Virtuelle Produkte im Rechner produzieren. In: VDI-Z, 141, (1999) 12, S. 26

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CHAPTER II THEORY II.1. Product Design Product design involves both the determination of which products are to be produced and the detailed design of individual products. Decisions regarding the products to be produced are generally made by top management based on input from marketing, manufacturing, and finance concerning projected economic performance. In other instances, the lead times to plan and build facilities, in the face of a dynamic product environment, might create a situation in which it is not possible to accurately specify the products to be produced in a given facility.

Figure II.1 Exploded assembly drawing

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If it is decided that the facility is to be designed to accommodate changes in occupants and mission, then a highly flexible design is required and very general space will be planned. On the other hand, if it is determined that the products to be produced can be stated with a high degree of confidence, then the facility can be designed to optimize the production of those particular products. The design of the product is influenced by aesthetics, function, materials, and manufacturing considerations. Marketing, purchasing, industrial engineering, manufacturing engineering, product engineering, and quality control, among others, will influence the design of the product. In the final analysis, the product must meet the needs of the customer. The drawing can be prepared and analyzed with computer aided design (CAD) systems. CAD is the creation and manipulation of design prototypes on a computer to assist the design process of the product. A CAD system consists of a collection of many application modules under a common database and graphics editor. The blending of computers and the human ability to make decisions enable us to use CAD systems in design, analysis, and manufacturing. During the facilities design process, the computer’s graphics capability and computing power allow the planner to visualize and test ideas in a flexible manner. The CAD system also can be used for area measurement, building and interior design, layout of furniture and equipment, relationship diagramming, generation of block and detailed layouts, and interference checks for process oriented plants.

II.2. Process Design The process designer or process planner is responsible for determining how the product is to be produced. As a part of that determination, the process planner addresses who should do the processing; namely, should be a particular product, subassembly, or part be produced in-house or subcontracted to an outside supplier or contractor? The ―make or buy‖ decision is part of the process planning function. In addition to determining whether a part will be purchased or produced, the process designer must determine how the part will be produced, which equipment will be used, and how long it will take to perform the operation. The final process design is quite dependent on input from both the product and schedule designs. This will explained later in sub-chapter II.6.

II.3. Schedule Design Schedule design decisions provide answers to questions involving how much to produce and when to produce. Production quantity decisions are referred to as lo size decisions; determining when to produce is referred to as production scheduling. In addition to how much and when, it is important to know how long production will continue; such a determination is obtained from market forecasts. Schedule design decisions impact machine selection, number of machines, number of shifts, number of employees, space requirements, storage equipment, material handling equipment, personnel requirements, storage policies, unit load design, building size, and so on. Consequently, schedule planners need to interface continuously with marketing and sales personnel and with the largest customers to provide the best information possible to facilities design planners. To plan a facility, information is needed concerning production volumes, trends, and the predictability of future demands for the products to be produced. The less specify provided regarding product, process, and schedule design, the more Rezza Prayogi

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general purpose will be the facility plan. The more specific the inputs from product, process, and schedule design, the greater the likelihood of optimizing the facility and meeting the needs of manufacturing.

II.4. Facilities Design Once the product, process, and schedule design decisions have been made, the facilities planner needs to organize the information and generate and evaluate layout, handling, storage, and unit load design alternatives. Some tools frequently used by quality practitioners (e.g., Pareto chart) can be very useful in facilities planning efforts.

Product design

Facilities design Process design

Schedule design

Figure II.2 Relationship between product, process, and schedule design and facilities Planning

II.5. Computer Simulation Simulation is defined as an experimental technique, usually performed on a computer, to analyze the behavior of any real-world system. Simulation involves the modeling processor or a system where the model produces the response of the actual system to events that occur in the system over a given period of time. Simulation can be used to predict the behavior of a complex manufacturing or service system by actually tracking the movements and the interaction of the system components. The simulation software generates reports and detailed statistics describing the behavior of the system under study. Based on these reports, the physical layouts, equipment selection, operating procedures, resource allocation and utilization, inventory policies, and other important system characteristics can be evaluated. Simulation modeling has two important characteristics that set simulation apart from other forms of analysis. Simulation modeling is dynamic, in that behavior of the model is tracked over simulated time. A simple what-if analysis is static in nature. The state of a static model doesn’t change as a function of time. If we were simulate the roll of a die, then the output of the model would not affected by time. However, if we were to simulate the utilization or breakdown of a machine, or the accumulation of work-in-process inventory at a workstation, then these phenomena would not be static in nature. Equipment utilization or breakdown, material handling and transportation

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systems behavior, and interaction among various activities in a manufacturing cell, for instance, are dynamic in nature and the output of such models is a function of time. Secondly, simulation is a stochastic model rather than a deterministic one. For example; if the mean time to failure (MTTF) for a piece of equipment is 1000 hours, it does not mean that the equipment will necessarily fail once every 1000 hours. Such an expectation would create a deterministic model. In the real world, the breakdown follows a particular statistical distribution, that is, exponential , Weibull, and so on. A random simulation model allows for these real-life breakdowns or other random occurrences.

Figure II.3 Computer simulations in manufacturing facilities design Computer simulation and modeling are rapidly becoming important in the manufacturing and service segment of industry. Although computer simulation and modeling are not new to solving complicated mathematical problems or to providing insights into sophisticated statistical distribution, the power of the new generation software has dramatically increased the application of computer modeling as a problem-solving tool in the facilities design arena.

II.6. How to Conduct Successful Facilities Planning To conduct successful facilities planning we need to make a lot of manual calculation and using excel. Data need to be collected before we make a trial and error calculation. In this sub-chapter I will presented step by step how to do this, and a theory behind each step. II.6.1. Design Product Blueprints, bill of materials, assembly drawings, and model shop samples inform the facilities designer of the prime mission – a detailed description of what needs to be accomplished. The product design step is the source of this valuable information. The first question anyone would ask when assigning a new facility design Rezza Prayogi

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project is, ―What are we going to make?‖ The output of this product design step tells us exactly what we are going to manufacture. Blueprints, sketches, pictures, CAD (Computer-Aided Design) drawings, and model shop samples all communicates the idea of what we want to build. There will be drawings of each individual part of the product as in Figure II.4. These drawings will tell us the size, shape, material, tolerances, and finish. Assembly drawings (see Figure II.1) show many parts (if not all parts) and how they fit together. An exploded drawing is an especially useful drawing for the facilities designer because it helps us to visualize how the parts fit together. Centerlines are used to separate parts and the parts are aligned to show the assembly relationship. These give the facility designer clues to the sequence of assembly.

Figure II.4 Sample blueprint for production purpose When the facility designer is working on the assembly line layout, the exploded drawing will be the guide. The facility design cannot get started without blueprints or sketches. Either a parts list or a bill of materials will be provided to the facility designer by the product engineering department with each new product. The part list and bill of materials are the same thing and list all the parts that make up a finished product. This list includes part numbers, part names, the quantity of each part, what parts make up subassemblies, and may include material specifications, parts and raw material unit costs, and make or buy decisions. The make or buy decisions are a total management decision not just the product engineering department, but the parts list is a good place to indicate that decision. Table II.1 Indented Bill of Materials Level Part No. Part Name 0 STG1 Packaged grill 1 PP1 Bottom grill casting 1 PP2 Grease can wire 1 PP3 Top grill casting 1 PP4 Wood handle 1 STG4 Legs 2 STG8 Top support

Drwg. No. DWG1 PDWG1 PDWG2 PDWG3 PDWG4 DWG4 DWG8

Qty/Unit 1 1 1 1 1 4 2

Make/Buy M B B B B M M

The intended bill of material is also an important aid in the design of the facility and configuration of the work cells and assembly lines (see Table II.1). An indented bill of material provides the same basic information as the parts list. However, the indented bill of material presents the hierarchical structure of the product by identifying each assembly, subassembly, and the required or subordinate parts of each assembly or subassembly. The highest level of the product, or the finished assembly, appears on the top of the list and is given level number zero (0). Under this are listed the major assemblies and each is assigned as level one (1). The period before the numeral (1) serves to indent the major subassemblies from the main assembly. Under each subassembly, the required components which comprise that subassembly Rezza Prayogi

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are listed and numbered level two (2). In turn, under each component, subordinate parts are listed and each is numbered as level three (3). If a given level itself is comprised of multiple parts, those parts would be listed following the given level three part and would be numbered level four (4), and ad infinitum. The purpose of the periods before each level number is to offset or indent (hence indented bill of material) each level in order to enhance readability. The indented bill of material not only provides data regarding the composition of the final assembly, but it also provides valuable insight into the flow of parts and components in the final assembly. Companies themselves do not fabricate every part of their product. The parts that are purchased complete are called buyouts and can be fabricated cheaper by someone else. Some companies purchase every part complete from outside. These companies are called assembly plants. The part that we ―make‖ are basic requirements for the fabrication end of our facility. The product engineering department can be very helpful to the plant facility designer. It can point out special manufacturing problems, critical relationships, dimensions, and function. The product designer and the facility designer need to work closely together. The up-front communication and cooperation between the product designer and facility planner is one aspect of concurrent engineering. II.6.2. Takt Time and Scrap Rates Calculation II.6.2.1. Takt Time Takt time can be defined as the maximum time allowed to produce a product in order to meet demand. It is derived from the German word taktzeit which translates to clock cycle. There is a logic therefore to setting the pace of production flow to this takt time. Product flow is expected to fall within a pace that is less than or equal to the takt time. In a lean manufacturing environment, the pace time is set equal to the takt time. Takt Time is defined as: 𝑇𝑎 𝑇= 𝑇𝑑 Where: Ta = Net Available Time to Work eg. [minutes of work / day] Td = Total demand (Customer Demand) eg. [units produced / day] T = TAKT Time eg. [minutes of work / unit produced] Net available time is the amount of time available for work to be done. This excludes break times and any expected stoppage time (for example scheduled maintenance, Team Briefings etc). As an example, if you have a total of 8 hours in a shift (gross time) less 30 minutes lunch, 30 minutes for breaks (2 x 15 mins), 10 minutes for a Team Brief and 10 minutes for basic Operator Maintenance checks, then; Net Available Time to Work = (8 hours x 60 minutes) - 30 - 30 - 10 - 10 = 400 minutes. If Customer Demand was, say, 400 units a day and you were running one shift, then your line would be required to spend a maximum of one minute to make a part in order to be able to keep up with Customer Demand. In reality, people can never maintain 100% efficiency and there may also be stoppages for other reasons, so allowances will need to be made for these instances and thus you will set up your line to run at a proportionally faster rate to account for this. Rezza Prayogi

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Takt time has direct implications concerning the allowable time for completing individual steps in a production process. This is the case for both steps that modify (form, assemble, finish…) the product and also the steps that observe and control (test, measure, adjust…) the process. Similarly steps which require a part or assembly of the product to have been put into an accurately fixtured position must be completed in less than the total takt time so that time is allowed for loading and unloading or positioning the part in addition to the time for actually performing the production step. The quicker that a measurement or test step can be completed, the less constraint is placed upon product motion between steps. For example, a measurement process that captures the entire information about a part at once will permit shorter total takt time and a higher pace of production flow. Elimination of the need to measure reduces this step best (See SMED). An implication of using takt time can be that work packages get reorganised. If worker one performs actions A1 through A5 and worker two performs actions A6 through A8 then a reduction in takt time may mean that there are now three work packages required to fit the new shorter/faster pace. They might be package 1 (A1 to A4), package 2 (A5 to A6) and package 3 (A7 to A8). So now we will have three people working to do the work that used to be achieved by two. This subdivision of workpackages rather than parallel working on unchanged packages of actions is a new idea to many. This way of working requires:  a very flexible workforce, that is willing to accept changes in their routines and workplace  requires a multi-skilled workforce, since now people may be asked to 'pick-up' actions currently performed by others  flexible workcells, since what is being done by two people today may need to accommodate three people tomorrow  increases hand-offs, so these must have no significant overhead  keeps the workflow simple and easy to manage, so whether the process will deliver is clear to all  has been observed to speed up individual steps in production, because the new context of each action encourages innovation. It will be obvious that this kind of capacity replanning is not something that will be desirable every week. It is therefore important that the varying part of Takt time, the customer demand, should have been leveled before this kind of work replanning is undertaken. That leveling is looked at elsewhere and that therefore this style of capacity modification should be undertaken to meet long term customer demand changes and not weekly forecasts. II.6.2.2. Scrap and Rework Although quite undesirable, manufacturing operations do produces scrap or unusable parts. Furthermore, often here is a need to redo an operation simply because the part was not produce within the desired specifications the first time. This is called rework. Scrap and rework result in an inefficient and wasteful use of the facilities resources. Every effort should be made to eliminate such waste. However, as long as we have to deal with scrap and rework, we cannot ignore their demand on our production time. Quality and production department have historical data that can indicate the level of rework and scrap for each operation. In determining the plant rate, or takt time, we must include scrap and rework rates into our calculations. Indeed, it is also prudent to add into these calculations the need for spare or replacement parts. The general formula is stated as: Rezza Prayogi

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𝐼=

Master Thesis

𝑜𝑢𝑡𝑝𝑢𝑡 1 − %𝑠𝑐𝑟𝑎𝑝1 1 − %𝑠𝑐𝑟𝑎𝑝2 1 − %𝑠𝑐𝑟𝑎𝑝3 … (1 − %𝑠𝑐𝑟𝑎𝑝 𝑛)

To illustrate, if we need 2000 part/day with 3 operations, each operation has its own scrap rates. Operation 1 is 30%, operation 2 is 25%, operation 3 is 5%. We calculate how much we need this part is: 2000 𝐼= = 2,125 𝑢𝑛𝑖𝑡𝑠 1 − 0,03 1 − 0,025 1 − 0,005 II.6.3. Process Design The process designer determines how the product and all its components will be made. The information provided by the process designer would include the following: 1. The sequence of operation to manufacturing every part in our product (they ―make‖ parts only because the ―buy‖ parts will not be our company’s problem) 2. The needed machinery, equipment, tools, fixtures, and so on 3. The sequence of operations in assembly and Packout 4. The time standard for each element of work 5. The determination of the conveyor speeds for cells, assembly and Packout lines, and paint or other finishing systems 6. The balance of the work loads of assembly and Packout lines 7. Load work cells 8. The development of a workstation drawing for each operation using all the principle of motion economy and ergonomics. Process design can be divided into two broad categories, fabrication and assembly. Fabrication process design is initially planned on a route sheet. Assembly and Packout process design uses the techniques charts and assembly line balancing. II.6.3.1. Fabrication The sequence of steps required to produce (manufacture) a single part is referred to as the routing. We route the part from the first machine to the second machine and so on until we have a finished part that will be united with other parts. The form used to describe this routing is called the route sheet. II.6.3.1.1. Route Sheet A route sheet (see Table II.2) is required for each individual fabricated part of our product (make part). If our finished product that is to be manufactured has 30 different parts and we buy 10 from outside the company (buyouts), and make 20 parts ourselves, we will need 20 route sheets. The route sheet lists the operations required to make that part in proper sequence. The route sheet gets its name from the way it is used. A copy of the route sheet would be issued by the production and inventory control department showing the order quantity. The route sheet would accompany the material from operation to operation telling the operators what to do. The route sheet will tell the plant personnel about the part number, part name, quantity to produce, operation number, operation description, machine number, machine name, tooling needed, and time standard.

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Table II.2. Route Sheet for one part Part No. Part Name Drawing No. STG13 Knob DWG13 Operation No. 75

Operation Description Molding

Machine

65

Trimming

Ergonomic Cutters

NISSEI NS60

Machine No. NS60

Cycle Fraction Pieces/ Time Equipment Hours

Hours/ pieces

Hours/ 1000

0,125

0,194

480

0,00208

2,083

ERGCT

0,060

0,093

1000

0,001

1

The route sheet ends with the last operation prior to being assembled with other parts. For example, if three parts are going to be welded together, the individual parts lose their identity once joined with other parts, so that the route sheet would end before welding. If an individual part goes through a clean, paint, and bake operation before being assembled, then the clean, paint, and bake procedure would be included on the route sheet. The sequence of operations as shown on the route sheet affects the proper layout of the equipment on the production floor. We want the material to flow smoothly through the plant from the raw material stores to the first operation, to the second operation whose machine is right next to the first machine. This will ensure that the part travels as short a distance as possible. Process-oriented layouts are where you collect all like machines together and bring all parts to them, where productoriented layouts place machine where they are needed to eliminate excessive moving. Skipping over machines and backtracking will result from process layouts and must be discouraged because it adds costs without adding to the value. When many parts are fabricated in one group of machines (called a process layout), jumping around may be necessary, but we want to minimize this jumping, skipping and backtracking. There are two ways to change the sequence in order to make the flow through the plant smoother: 1. Change the route sheet (paper change) if possible so that the sequence of operation agrees with the other parts or the plant layout. 2. Change the physical layout of the machines so that the machines are in the correct sequence. Changing the paperwork is our first choice because it is the cheapest way. Time standards are an important part of the route sheets. Time standards are used to determine how many machines are needed in our layout. They are another piece of information that may come from another group within the manufacturing engineering department, but in many companies, time standards are developed by the manufacturing facilities designer. II.6.3.1.2. The Number of Machines Needed How many machines should we buy? This question can only be answered when we know: 1. How many finished units are needed per day? 2. Which machine runs what parts? 3. What is the time standard for each operation?

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How many finished units are needed per day? The marketing department tells us how many products to produce (manufacture) per day. Which machine runs what parts? The route sheets produced in the previous section will tell us which machines are needed to produce each part. What is the time standard for each operation for each part? The time standard for every operation on every part is in both pieces per hour and decimal minute. We need the decimal minute time standards to compare with the Takt Time. Once we know the plant rate (takt time), the machines to be used, and the time standards, we divide the time standard (decimal minute) by the plant rate. The resultant number of machines should be in two decimal places (i.e., 0,46 machine). Once all the machine requirements for each operation have been calculated, we total similar machine requirements and round up recommending the purchase of enough machines. Always round up on the total machines, otherwise a bottleneck will be created and we will not produce exact number of product per day, unless our plant work overtime. If due to economic considerations, rounding up cannot be justified, overtime may need to be planned for these operations in order to meet production requirements and to alleviate bottlenecks. If investment can be justified, and the production volume is warranted, then rounding up is recommended. This information on the number of machines required will be used later to determine the number of square feet of floor space needed in our fabrication department. II.6.3.2. Work Cell Load Chart The work cell load chart is different from the previous techniques in that it does not have to be for a complete part or product, but it could be for only a few operations. We could end up with a complete part; however, that it not the goal of a work cell. A work cell is a collection of equipment required to make a single part or a family of parts with similar characteristics. This equipment is placed in a circle around an operator or operators (see Figure II.5). The operator (most often a single operator) then takes a part from the in-basket and moves that part around the circle of equipment. Equipment is usually automatic machines that only need to be loaded, activated, and then unloaded. Once the machine is loaded and activated, the operator moves the just completed part from the first machine to the second, where the operator removes the previous part and loads the next part. This process continues around the cell: taking parts out of one machine, putting new parts back into this machine, then activating that machine until arriving at the last machine, where the part is removed, inspected, and placed in the finished parts basket. Work cell are being developed at a very fast rate because they 1. Significantly reduce setup time 2. Eliminate all storage between operations 3. Eliminate most of the moving time between operations 4. Eliminate delays spent waiting for the next machine 5. Reduce cost 6. Reduce inventory (work-in-process reductions) 7. Reduce manufacturing in process time

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In

Master Thesis

Drill# 1 4 holes

Drill# 2 4 holes

4

6

2 8

Out

C‖ bore 8 holes

14 12 Tap 8 holes

10 0 Ream 8 holes

Figure II.5. Work cell Layout These are the goals of lean manufacturing and a good description of eliminating ―muda‖ or waste. The work cell concept considers operator (utilization) to be more important than machine utilization. Work cell load charts are a special operations chart used for multi-machine situations. Work cell load charts will visually show the operator time, machine time, and walking time required to run a work cell to produce one part per cycle using many machines. The result of the work cell load chart will show us the total cycle time, proper utilization, and machine utilization. Because they are visual, work cell load charts help people to see problems and to make improvement on the operation by properly loading the operator, operators, and/or machines. A work cell will appear on the route sheet as one operation. II.6.3.3. Assembly and Packout Process Analysis Once all parts are produced by the fabrication departments or received from the suppliers and available for assembly, new analytical tools are needed. Subassembly, welding, painting final assembly, and Packout are all function included in this area of the plant. II.6.3.3.1. The Assembly Chart The Assembly Chart shows the sequence of operations in putting the product together. Using the exploded drawing and the part list, the layout designer will diagram the assembly process. The sequence of assembly may have several alternatives. Time standards are required to decide which sequence is best. This process is known as assembly line balancing. II.6.3.3.2. Assembly Line Balancing The purpose of the assembly line balancing technique is: 1. To equalize the work load among the assemblers 2. To identify the bottleneck operation 3. To establish the speed of the assembly line 4. To determine the number of workstations 5. To determine the labor cost of assembly and Packout Rezza Prayogi

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6. To establish the percentage workload of each operator 7. To assist in plant layout 8. To reduce production cost The assembly line balancing technique builds on the assembly chart (Figure II.6) time standards and the plant rate (takt time). The objective of assembly line balancing is to give each operator as close to the same amount of work as possible. This can only be accomplished by breaking the taks into the basic motions required to do every single piece of work and reassembling the tasks into jobs of near equal time value. The workstation or stations with the largest time requirement is designated as the 100% station and limits the output of the assembly line. If industrial engineers want to improve the assembly line (reduce costs), they would concentrate on the 100% station. Reduce the 100% station in our example below by 1% and save the equivalent of 0,25 people, a multiplying factor of 25 to 1.

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Grill Legs (2) SA1

Spot Weld (×2)

P1

Paint

Side Support (1) Paint

Control Panel (1) Bottom Support (2)

SA3 Paint

Paint

P3

P2

Paint

Paint

Tank Holder (1)

Wood Slats (4)

SA2

SA4

SA5

Casting Ignitor Grates

SA6

Purchase Parts

Gas Valving Burner Feet & Knob Fasteners Instructions

SA7

Bagging

Poly Bag

Cardboard Box Staples

P.O

Cardboard Packing

Figure II.6. Assembly Chart II.6.3.3.3. Packout Packout work is considered to be the same as assembly work as far as assembly line balancing is concerned. Many other jobs may be performed on or near the assembly line, but they are considered subassemblies and are not directly balanced

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to the line because subassemblies can be stockpiled. Their time standards stand on their own merit. II.6.4. Equipment and Space Used II.6.4.1. Workstation Design Choosing equipment comes from process design, but the space needed and workstation design must be calculated separately using ergonomics. The result of ergonomics and workstation design is a workstation layout, and the workstation layout determines the space requirements. The manufacturing department’s total space requirements are just a total of individual space requirements plus a little extra factor. Ergonomics is the science of preventing muscular/skeletal injuries in the workplace. It is the study of workplace design and the integration of workers with their environment. Ergonomic considerations include employee size, strength, reach, vision, cardiovascular capacities, cognition, survivability, and cumulative muscular/skeletal injuries. The golden rule may be stated as follows: Design the work or the workstation so that the task fits into the person rather than attempts to force the human body or psyche to fit into the job. The resulting workstation design is a drawing, normally a top view, of the workstation, including the equipment, materials, and operator space. Designing workstations has been an activity performed by industrial and manufacturing engineers for nearly a century. During this period of time, the profession has developed a list of principles of ergonomics and motion economy that all new engineers should learn and apply. When these principles are applied to the design of a workstation, the most efficient and safe motion patterns will result. ―Where to start?‖ is the first question most often asked by new workstation designer. The answer is very simple – start anywhere! No matter where you start in designing a workstation, another idea will come along making that starting point obsolete. Where to start depends a great deal on what is to be accomplished at that workstation. The cheapest way to get into production is usually the best rule for the starting point. The cheapest way means just that – the simplest machines, equipment, and workstation. Savings must justify any improvement on this most economical method. Therefore, the designer is free to start anywhere, then improve on the first method. The following information must be included in any workstation design: 1. 2. 3. 4. 5. 6. 7.

Worktable, machines, and facilities Incoming materials (materials, packaging and quantity must be considered) Outgoing material (finished product) Operator space and access to equipment Location of waste and rejects Fixture and tools Scale of drawing (see Figure II.7)

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Figure II.7. Workstation layout for Bending Machine A three-dimensional drawing would show an even greater amount of information. Any talented designer could attempt a three-dimensional design. II.6.4.2. Space Determination The space determination procedure for most production departments start with the workstation design. From each workstation layout, we measure the length and width to determine the square foot of each workstation. Multiplying the total square feet by 150% allows extra space (this could be 200% if management wants to provide a spacious layout, or a larger contingency allowance) for the aisle, work in process, and a small amount of miscellaneous extra room. It does not include restrooms, lunchrooms, first aid, tool rooms, maintenance, offices, stores, warehouse, shipping, or receiving. The extra 50 to 100% space added to the equipment space requirement will be used mostly for aisles. Aisles can be very space consuming. Table II.2 Example of Equipment Space Requirement Machine Name Operation Machine code JUTEC 850 Bender JTC850 DrillPress Drill 8062 TRADESMAN Lincoln Resitance Welder LR560 MINTER 300 Stamp MNS300 Big 800 Wood/Steel Saw B800 RYOBI Sander RBS SHARP Poly Bag J69 Ingersoll Rand Paint Booth IR800 NISSEI Injection Mold NS60

Space Required 106 ft2 = 9,85 m2 34 ft2 = 3,16 m2 67 ft2 = 6,23 m2 476 ft2 = 44,22 m2 152 ft2 = 14,12 m2 31 ft2 = 2,88 m2 64 ft2 = 5,95 m2 440 ft2 = 40,88 m2 73 ft2 = 6,78 m 2

Small space consuming items such as an air compressor or drinking fountain may be included in this 50% extra area, but large area requirements must be designed and planned.

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Master Thesis

II.6.5. Material Handling Equipment Used II.6.5.1. Material Handling Definition Material Handling is the function of moving the right material to the right place, at the right time, in the right amount, in sequence, and in the right position or condition to minimize production costs. Material control systems are an integral part of modern material handling systems. Part numbering systems, location systems, inventory control systems, standardization, lot size, order quantities, safety stocks, labeling, automatic identification techniques (bar coding) are only some of the systems required to keep industrial plants material moving. Material handling can be broadly defined as all movement of materials in a manufacturing environment. The American Society for Mechanical Engineers (ASME) defines material handling as the art and science involving the moving, packaging, and storing of substances in any form. Material handling may be thought of as having five distinct dimensions: movement, quantity, time, space and control. Movement involves the actual transportation or transfer of material from one point to the next. Efficiency of the move as well as the safety factor in this dimension is of prime concerns. The quantity per move dictates the type and nature of the material handling equipment and also cost per unit for the conveyance of the goods. The time dimension determines how quickly the material can move through the facility. The amount of the work in process, excessive inventories, repeated handling of the material, and order delivery lead times are affected by this aspect of the material handling systems. The space aspect of the material handling is concerned with the required space for the storage of the material handling equipment and their movement, as well as the queuing or the staging space for the material itself. The tracking of the material, positive identification, and inventory management are some aspects of the control dimension. Material handling is also an integral part of plant layout. They cannot be separated. A change in the material handling system will change the layout, and a layout change will change the material handling system. Material can be moved by hand or by automatic methods, material can be moved one at a time or by the thousands, material can be located in a fixed location or at random, or material can be stored on the floor or high in the sky. The variations are limitless and only by cost comparison of the many alternatives will the correct answer emerge. The proper material handling equipment choice is the answer to all our questions in this section. A material handling equipment list will include over 500 different types (classifications) of equipment, and if we multiply this number by the different models, sizes, and brand names, several thousand pieces of equipment are available for our use. Material handling equipment has reduced the drudgery of work. It has reduced the cost of production and has improved the quality of work life for nearly every person in industry today. But the handling of material is attributed to more one-half of all industrial accidents. Material handling equipment can eliminate manual lifting and also can cause injury, so do not forget about safety aspects. II.6.5.2. Goals of Material Handling The primary goal of material handling is to reduce unit costs of production. All other goals are subordinate to this goal. But the following sub-goals are a good checklist for cost reduction: Rezza Prayogi

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1. Maintaining or improve product quality, reduce damage, and provide for protection of materials. 2. Promote safety and improve working conditions. 3. Promote productivity: a. Material should flow in a straight line. b. Material should move as short a distance as possible. c. Use gravity! It is free power. d. Move more material at one time. e. Mechanize material handling. f. Automate material handling. g. Maintain or improve material handling/production ratios. h. Increase throughput by using automatic material handling equipment. 4. Promote increased use of facilities: a. Promote the use of the building cube. b. Purchase versatile equipment. c. Standardize material handling equipment. d. Maximize production equipment utilization using material handling feeders. e. Maintain, and replace as needed, all equipment and develop a preventive maintenance program. f. Integrate all material handling equipment into a system. 5. Reduce tare weight (dead weight) 6. Control inventory II.6.5.3. The 20 Principles of Material Handling The College Industrial Committee on Material Handling Education, sponsored by the Material Handling Institute, Inc. and the International Material Management Society has adapted the 20 principles of material handling. The principles are guidelines for the application of sound judgment. Some principles are in conflict with others, so only the situation being designed will determine what is correct. The principles will be a good checklist for improvement opportunities. 1. Planning principle. Plan all material handling and storage activities to obtain maximum overall operating efficiency. 2. System principle. Integrate as many handling activities as is practical into a coordinated system of operations, covering vendor, receiving, storage, production, inspection, packaging, warehousing, shipping, transportation, and customer. 3. Material flow principle. Provide an operation sequence and equipment layout optimizing material flow. 4. Simplification principle. Simplify handling by reducing, eliminating, or combining unnecessary movement and/or equipment. 5. Gravity principle. Utilize gravity to move material wherever practical. 6. Space utilization principle. Make optimum utilization of building cube. 7. Unit size principle. Increase the quantity, size, or weight of unit loads or flow rate. 8. Mechanization principle. Mechanize handling operation. 9. Automation principle. Provide automation to include production, handling, and storage functions.

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10. Equipment selection principle. In selecting handling equipment, consider all aspects of the material being handled – the movement and the method to be used. 11. Standardization principle. Standardize handling methods as well as types and sizes of handling equipment. 12. Adaptability principle. Use methods and equipment that can best perform a variety of tasks and applications where special purpose equipment is not justified. 13. Dead weight principle. Reduce ratio of dead weight of mobile handling equipment to load carried. 14. Utilization principle. Plan for optimum utilization of handling equipment and manpower. 15. Maintenance principle. Plan for preventive maintenance and scheduled repairs of all handling equipment. 16. Obsolescence principle. Replace obsolete handling methods and equipment when more efficient methods or equipment will improve operations. 17. Control principle. Use material handling activities to improve control of production inventory and order handling. 18. Capacity principle. Use handling equipment to help achieve desired production capacity. 19. Performance principle. Determine effectiveness of handling performance in terms of expense per unit handled. 20. Safety principle. Provide suitable methods and equipment for safe handling. II.6.5.4. The Material Handling Problem Solving Procedure Step 1. Analyze the requirement to define the problem. Be sure the move is required. Step 2. Determine the magnitude of the problem. Cost analysis is best. Step 3. Collect as much information as possible-why, who, what, where, when, and how Step 4. Search for vendors. Suppliers often provide outstanding engineering and cost justification assistance. Step 5. Develop variable alternatives Step 6. Collect costs and savings data on all alternatives. Step 7. Select the best method. Step 8. Select a supplier. Step 9. Prepare the cost justification. Step 10. Prepare a formal report. Step 11. Make a presentation to management. Step 12. Obtain approvals (adjust as needed). Step 13. Place an order. Step 14. Receive and install equipment. Step 15. Train employees. Step 16. Debug (make it work) and revise as necessary. Step 17. Place into production. Step 18. Follow up to see what it is working as planned. Step 19. Audit performance to see that payback was realized.

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II.6.5.5. Material Handling Equipment II.6.5.5.1. Type of Material Handling Equipment There are literally thousands of pieces of material handling devices. These equipments vary from the most basic manual tools to the most sophisticated computercontrolled material handling systems that can incorporate a vast array of other manufacturing and control functions. Almost as varied and numerous are the classification strategy and methods of material handling equipment. Traditionally, material handling equipment may be grouped into four general categories. The first category is the fixed-path or point-to-point equipment. This class of equipment serves the material handling need along a predetermined, or a fixed path. The most common and familiar example of a fixed-path system is the train and the railroad track. The train can travel from any point to any point and serve any point along the track system. Conveyor systems, powered, gravity-fed, or otherwise operated, fall into this classification. Fixed-path material handling systems are also referred to as continuous flow systems. Automated guided vehicles (AGV) fall into this group. The fixed-area material handling system can serve any point within a threedimensional area of cube. A jib crane or a bridge crane would serve as an example to describe this category of material handling systems. A jib crane installed on a floor pedestal can move parts and other material from any point in the x, y, and z direction; however, this ability is limited within confines of the equipment. Automated storage and retrieval systems (ASRS) also fall into this category. The material handling equipment that can move to any area of the facility is referred to as variable-path variable-area equipment. All manual cars, motorized vehicles, and fork trucks can be pushed, dragged, or driven throughout the plant. What, then, would a jib crane that is installed on a mobile pedestal be called? Obviously, this is a compound material handling system. The crane is a fixed-area system and the pedestal is a variable-path vehicle. When the base is stationary the crane is confined within its reach. The forth category consists of all auxiliary tools and equipment such as pallets, skids, automatic data collection systems, and containers. How do we choose the proper piece of equipment from the thousands of material handling devices available to us? For the experienced project engineer or manager, this problem is not as great as it is for the novice. To assist the new facilities planner, the following organization of material handling equipment is suggested. This organization follows the flow of material from the receipt of material to the warehousing of that material as follows: 1. Receiving and shipping (they are similar) 2. Stores 3. Fabrication 4. Assembly 5. Packaging 6. Warehousing This organization lends itself to specific problem-solving situations. Two additional areas of material handling are: 7. Bulk material handling 8. Automatic storage and retrieval systems

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The systems principle of material handling states that material handling devices should be used in as many as possible and that everything fits (works) together. II.6.5.5.2. Bulk Material Handling Bulk Material Handling is an engineering field that is centered around the design of equipment used for the transportation of materials such as ores and cereals in loose bulk form. It can also relate to the handling of mixed wastes. Bulk material handling systems are typically comprised of moveable items of machinery such as conveyor belts, stackers, reclaimers, bucket elevators, shiploaders, unloaders and various shuttles, hoppers and diverters combined with storage facilities such as stockyards, storage silos or stockpiles. The purpose of a bulk material handling facility is generally to transport material from one of several locations (i.e. a source) to an ultimate destination. Providing storage and inventory control and possibly material blending is usually part of a bulk material handling system. Bulk material handling systems can be found on mine sites, ports (for loading or unloading of cereals, ores and minerals) and processing facilities (such as iron and steel, coal fired power stations refineries). In ports handling large quantities of bulk materials continuous ship unloaders are replacing gantry cranes.

Figure II.8. Seattle Smith cove grain terminal II.6.5.5.3. Forklift truck A forklift truck, a lift truck, a High/Low or a forklift and sideloader is a powered industrial truck used to lift and transport materials, normally by means of steel forks inserted under the load. Forklifts are most commonly used to move loads stored on pallets. The forklift was developed in the 1920s by various companies including the transmission manufacturing company Clark (today known as Clark Material Handling Company) and the hoist company Yale & Towne Manufacturing (today known as Yale Materials Handling Corporation)[1]. It has since become an indispensable piece of equipment in manufacturing and warehousing operations.

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Figure II.9. Forklift with Driver There are many national and/or continental associations related to the industrial trucks. The three major ones are the Industrial Truck Association (North America), the Fédération Européenne de la Manutention (Europe), and the Japan Industrial Vehicles Association (Japan). There are many significant contacts among them and they have established joint statistical and engineering programs. One program is the WITS (World Industrial Trucks Statistics) published every month to the association memberships. The statistics are separated by area (continent), country, and class of machine. While the statistics are generic, and do not count production from most of the smaller manufacturers, the information is significant for its depth. These contacts have brought to a common definition of the Class System, which all the major manufacturers adhere to. Following is the list of the more common truck types, from the smallest to the biggest: 

            

Hand pallet truck (a "pump truck", or a "chep truck", or a "hand-jack", a simple mechanism whereby hand-pumped hydraulics raise or lower a single pallet simply to provide clearance from the floor for manual (hand) pulling; heavy loads are unwieldy or risk injury to operators.) (Separate article to follow with photographs.) Walkie low lift truck (powered pallet truck, usually electrically powered) Rider low lift truck Towing tractor Walkie stacker Rider stacker Reach truck (small forklift, designed for small aisles, usually electrically powered) Electric counterbalanced truck IC counterbalanced truck Sideloader Telescopic handler Slip Sheet machine Walkie Order Picking truck Rider Order Picking truck (commonly called an "Order Picker"; like a small forklift, except the operator rides up to the load and transfers it article by article)

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Articulated Very Narrow Aisle Counterbalanced trucks (commonly called "Bendi Truck") Guided Very Narrow Aisle truck - 'Man Down' (a type of reach truck designed for aisles less than five feet wide) and 'Man Riser' Combination Order Picker/ Stacker truck

Figure II.10. Forklift Classes and Lift Codes A typical 'Counterbalance' forklift may be generally described as follows:  The truck proper, which is a motive machine with wheels and/or tracks powered through a drive train.  A liquefied petroleum gas–, petrol- or diesel fueled internal combustion engine, or an electric motor(s) either direct current or alternating current powered by either a battery or fuel cells.  The mast, which is the vertical assembly that does the work of raising, lowering, and tilting the load; the mast is either hydraulically operated consisting of one or more cylinder(s) and interlocking rails for lifting and lowering operations and for lateral stability, or it may be chain operated with a hydraulic motor providing motive power.

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The carriage, which comprises flat metal plate(s) and is moved along the mast either by means of chains, or by being directly attached to the hydraulic cylinder. One or more forks, which are the L-shaped members that engage the load. The back vertical portion of the fork attaches to the carriage most often by means of a hook or latch (Class I to IV forks), while some forks use a shaft mount. The front horizontal portion (which is usually tapered for ease of insertion) is inserted into or under the load, usually on a pallet (also known as a "skid"). Alternatively, a variety of other equipment is available, including slipsheet clamps, carton clamps, carpet rams, pole handlers, container handlers, roll clamps and others. A load back rest is fitted when the load is higher than the top of the carriage, and is a rack-like extension either bolted or welded to the carriage to prevent the load from shifting backward. Rider operated machines have a driver's overhead guard, which is a metal roof, supported by posts, that helps protect the operator from any falling objects. The cab, which may contain a seat for the operator, along with the control pedals, steering wheel, levers, and switches for controlling the machine and a dashboard containing operator readouts. The cab may be open, or closed, but is bounded by the cage-like overhead guard assembly. Counterbalance machines have a counterweight, which is a heavy iron mass attached to the rear of the machine, necessary to compensate for the load. In an electric forklift, the large lead-acid battery itself may serve as part of the counterweight. At the other end of the spectrum from the Counterbalance truck are more 'high end' specialist trucks such as: Articulated Counterbalance Trucks These are, unlike most other lift trucks, front wheel steer, and are a hybrid VNA (Very Narrow Aisle) truck designed to be both able to offload trailers and place the load in narrow aisle racking. Increasingly these trucks are able to compete in terms of pallet storage density, lift heights and pallet throughput with Guided Very Narrow Aisle trucks. Guided Very Narrow Aisle trucks

Figure II.11. Diesel Electric Forklift handling logs These are rail or wide guided and available with lift heights up to 12 metres (40') non top-tied and 30 metres (98') top-tied. Two forms are available; 'man-down' Rezza Prayogi

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and 'man-riser' where the operator elevates with the load for increased visibility or for multilevel 'break bulk' order picking. This type of truck, unlike Articulated Narrow Aisle Trucks, requires a high standard of floor flatness. Forklift trucks are available in many variations and load capacities. In a typical warehouse setting most forklifts used have load capacities of around one to five tons, though machines of over 50 tonnes capacity have been built and operated. Unlike cars, forklifts are normally rear-steer. In addition to a control to raise and lower the forks (also known as blades or tines), the operator can tilt the mast to compensate for a load's tendency to angle the blades toward the ground and risk slipping off the forks. Tilt also provides a limited ability to operate on non-level ground. Some machines also allow the operator to move the tines and backrest laterally (side-shift), allowing easier placement of a load. To aid the handling of skids that may have become excessively tilted and other specialty material handling needs, some forklifts are fitted with a mechanism that allows the tines to be rotated. In addition, a few machines offer a hydraulic control to move the tines together or apart, removing the need for the operator to get out of the cab to manually adjust for a differently sized load. Roll and barrel clamp attachments for handling barrels, kegs, or paper rolls also have a control to operate the clamp pads that grab the load, such attachments also usually have a rotate function so that a vertically stored paper roll can be inserted into the horizontal intake of a printing press. In some locations (such as carpet warehouses) a long metal pole is used instead of forks to lift large rolls. Similar devices, though much larger are used to pick up 40 tonne metal coils. Another variation, used in some manufacturing facilities, utilizes forklift trucks with a clamp attachment that the operator can open and close around a load, instead of forks. Products such as cartons, boxes, etc., can be moved with these trucks. The product to be moved is squeezed, lifted, and carried to its destination. These are generally referred to as "clamp trucks". Skilled forklift operators annually compete in obstacle and timed challenges at regional forklift rodeos Standards Forklift safety is subject to a variety of standards world wide. The most important standard is the ANSI B56—of which stewardship has now been passed from the American National Standards Institute (ANSI) to the Industrial Truck Standards Development Foundation after multi-year negotiations. ITSDF is a non-profit organization whose only purpose is the promulgation and modernization of the B56 standard. Other standards have been promulgatd by the U.S Occupational Safety and Health Administration and the United Kingdom's Health and Safety Executive. Lift truck operators must be trained and certified. General Forklifts are rated for loads at a specified maximum weight and a specified forward centre of gravity. This information is located on a nameplate provided by the manufacturer, and loads must not exceed these specifications. In many jurisdictions it is illegal to remove or tamper with the nameplate, without the permission of the forklift manufacturer. An important aspect of forklift operation is that many have rear-wheel steering. While this increases maneuverability in tight cornering situations, it differs from a Rezza Prayogi

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driver’s traditional experience with other wheeled vehicles as there is no caster action; it is unnecessary to apply steering force to maintain a constant rate of turn. Another critical characteristic of the forklift is its instability; the forklift and load must be considered a unit, with a continually varying centre of gravity with every movement of the load. A forklift must never negotiate a turn at speed with a raised load, where centrifugal and gravitational forces may combine to cause a disastrous tipover accident. The forklift will be designed with a load limit for the forks, which is decreased with fork elevation and undercutting of the load (i.e. load does not butt against the fork "L"). A loading plate for loading reference is usually located on the forklift. A forklift must not be used as a personnel elevator without the fitting of specific safety equipment, such as a "cherry picker" or "cage".

Figure II.13. Load Capacity Chart II.6.6. Cost Calculation II.6.6.1. How Much Will Our Product Cost? At the earliest point in a new product development project, the anticipated cost must be determined. A feasibility study will show top management the profitability of a new venture. Without proper, accurate costs, the profitability calculations would be nothing but a guess. Product costs consist of: Typical % Manufacturing costs 50%

Direct labor Direct materials Overhead costs

8 25 17

Front-end costs

Sales&Distribution costs Advertising Administrative overhead 50% Engineering Profit

15 5 20 3 7

100% Direct labor cost is the most difficult component of product cost to estimate. Time standards must be set prior to any equipment purchase or material availability. Time standards are set using predetermined time standards or standard data from blueprints and workstation sketches. The time standards are collected on something like the operations chart. Rezza Prayogi

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Direct material is the material that makes up the finished product and is estimated by calling vendors for a bid price. Normally, 50% of the manufacturing cost (direct labor + direct materials + factory overhead) is direct material cost. On the operating chart, raw materials are introduced at the top of each line. Buyout parts are introduced at the assembly and Packout station. Factory overhead costs are all expenses of running a factory, except the previously discussed direct labor and direct material. Factory overhead is calculated as a percentage of direct labor. This percentage is calculated using last year’s actual costs. Labor cost is the most difficult cost to calculate of all the costs that make up the selling price. How could you calculate the selling price without time standards? Anything else is a guess. Cost-estimating is an important part of any industrial engineering program and should be a complete course covering operations, product, and project costing. Motion and time study would, of course, be a prerequisite. II.6.6.2. Material Handling Cost Material handling equipment can be very expensive, so all investments should be cost-justified. The lowest overall cost per unit gives us the best answer. If a very expensive piece of equipment reduces unit cost, it is a good purchase. If it does not reduce unit cost, it is a bad purchase. Non-powered equipment can be very cost efficient and should always be considered. Gravity chute, rollers, hand carts, and hand jacks are only few of the many very popular methods of moving material economically. Safety, quality, labor, power, and equipment costs must all be included in the unit costs. If someone is expected to lift a 100lbs load while performing a task, the long term effect of the activity, or the cumulative trauma disorder, associated with this job must be considered. Ergonomic consideration of job design dictates that some type of material handling system such as a hydraulic or pneumatic lifting device should be studied. If taken in isolation, the dollar cost may not be justifiable; however, the longterm safety considerations will certainly prove the investment to be a wise one. An automobile manufacturer discovered that a simple manipulator device, which assisted in lifting and turning the car seats while installing them, prevented serious and chronic lower back pain and injury to the assembly line workers. II.6.6.3. Cost Reduction Formula The cost reduction formula is valuable when working with manufacturing facilities design and material handling. The cost reduction formula is a word formula that looks like this: Ask For Every So We Can Why Operation Eliminate Who Transportation Combine What Inspection Change sequence Where Storage Simplify When Delay How We ask the six questions (column one) about everything that can happen to a part flowing through our manufacturing facility (column two) so that we can eliminate steps, combine steps, change sequence of steps, or simplify (column three). This requires that we study the product of our company in order to identify every step in the process. This is a big job and is why the company will pay you the big bucks. The best Rezza Prayogi

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advice you can get is not to take shortcuts or to skip steps in the proposed manufacturing facility design procedure. There is no easy way, just hard work and attention to detail. The five (5) S’s and five why’s are also cost reduction attitudes that will help to reduce costs. The 5 S’s principles are: 1. Sifting (organization). Keeping the minimum of what is required will save space (affects the facility layout), inventory, and money. 2. Sorting (arrangement). Everything has a specific place, and everything in its place is a visual management philosophy that affects the facility layout. 3. Sweeping (cleaning). A clean plant is a result of a facility layout that has been thought to provide room for everything. 4. Spick and span (hygiene). A safe plant is a result of good layout planning. 5. Strict (discipline). Following the procedures and standardized methods and making them a habit will keep the plant operating efficiently and safely. The five ―why’s‖ is a way of thinking that will ensure that the solution to a problem is not a symptom of the problem, but rather, the base cause. For example: we had a machine break down. Why? 1. The machine jammed up. Why? 2. The machine was not cleaned. Why? 3. The operator did not clean it out at regular intervals. Why? 4. Lack of training? Why? 5. The supervisor forgot. They make a written instruction to be mounted on the machine. It will not happen again. We could have asked six or seven why’s – the important thing is to arrive at a final solution that will eliminate the problem from occurring again. II.6.7. Tips Here are some tips from me on how to make this facilities planning run faster, more efficient, and decrease error. 1. Design Product use Solidworks or CATIA. 2. Takt time, scrap rates, process design, space, cost calculation use Excel. 3. Plant layouts use Visio Template. 4. Process Design and Factory Simulation using Delmia. 5. Material Handling and Production equipment data, search in product catalog

II.7. How to Build Digital Factory II.7.1. Getting Started with Delmia Quest II.7.1.1. Introduction The QUEST discrete event simulation package is a very powerful simulation tool that will allow you to model and analyze complex systems. In this sub-chapter we will discuss the best ways to begin using QUEST. Topics covered include starting QUEST and the options available at startup, the file system and user interface, and the various controls and navigation tools provided in the product. I want to show you how to start Delmia QUEST, load a model, and navigate through the various menus and controls. QUEST runs on both UNIX and Windows based systems. The user interface is similar between platforms, with minor differences taking advantage of the specific strengths of each platform. It only works in Windows NT systems include in these NT categories: Windows NT, Windows 2000, Windows XP, Windows Vista, and not in Windows 95 and Windows 98. Rezza Prayogi

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II.7.1.2. Starting QUEST The installation process will create a menu item under Programs in your Start menu in the Windows version. It will also place a shortcut on your desktop. QUEST is launched with a batch file (Windows) or script (UNIX). The batch file sets the various environment variables and then invokes the executable file that starts QUEST. The batch file is called quest .bat (Windows) or quest (UNIX) and is found in the DELMIA/quest directory. Shown below is the standard quest .bat file for the Windows platform. @echo off set DELMIA_PRODUCT=QUEST set DELMIA PATH=C:\DELMIA _ set PROD_LIB=%DELMIA_PATH%\%DELMIA_PRODUCT%\ if ”%TMP%” == ”” set TMP=C:\tmp if ”%TMPDIR%” == ”” set TMPDIR=C:\tmp set LM _LICENSE _FILE= %DELMIA_PATH%\license\license.dat set VIEWER _PROG=C: \PROGRA~1\Netscape\NAVIGA~1\Program\Netscape .exe set DELMIA_DOC_VIEWER=%VIEWER_PROG% %PROD_LIB%docs\%DELMIA_PRODUCT%_HOME\HOMEPAGE . html cd %PROD_LIB% echo initializing and running % DELMIA_PRODUCT% start /max %DELMIA_PRODUCT%.exe %1 %2 %3 %4 %5 %6 %7 %8 %9

There are a number of setup options that you can configure in order to customize the way QUEST starts. Customizing your startup can significantly reduce the time it takes to get started each day. It is also useful in creating a predefined format for organizing libraries and loading models. If you wish to locate QUEST or any of its components under a different directory structure then you will need to make these changes when the product is installed. It is not advisable to move the QUEST system or data files after the product has been installed. Modifying the quest .bat file shown above generally creates a customized startup. The last line that launches the %DELMIA_PRODUCT%.exe takes in up to nine arguments. These are indicated by the %1 through %9 shown above. These options may be invoked by supplying the arguments to the quest .bat file in the command prompt or by deleting the %1 through %9 in the batch file and keying in the desired argument. For example, to launch QUEST with a specific license file the last line of the quest .bat file is modified as shown below: start /max %DELMIA_PRODUCT%.exe –L 530

This instructs QUEST to use license number 530. The various options that you can invoke when launching QUEST are shown below:  -AA - Launches QUEST on an SGI RealityEngine workstation using anti-aliasing. The optional value is 4, 8, or 16 and is the number of pixel samples that the hardware uses when rendering. The higher the number, the better the quality of the anti-aliasing but performance will be Rezza Prayogi

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lower. Default value for is 4. -f - Starts QUEST in full screen mode. -i - QUEST loads with the specified string as the window and icon title. When used on the command line, cannot contain any blank characters. If this option is specified inside of the startup script, a multiword string can be specified using single quotes, i.e., -i 'Version 2.4'. -r - Automatically loads the specified model upon startup. The .qpthfig should include all necessary configuration files. -v (Viewport) - Launches QUEST with the screen viewport set based on the four parameters entered. The first two parameters represent the X dimension of the screen. The second two parameters represent the Y dimension. The zero-zero point for the window is located at the bottom, left-hand corner of the screen. The parameter values are ratios. For the X parameters, they are the ratio of the desired window height to the screen resolution. For the Y parameters, they are the ratio of the desired window width to that of the screen. This is useful when you want to work in a window of a specific size. For example, when you wish to create a NTSC video from a 1280*1024 resolution monitor, the command line would be %DELMIA2PRODUCT%.exe -v 0.0 0.5 0.0 0.46875, resulting in a window of 640*480 resolution. On a Windows platform this option is the same as the -w option below. On a Unix platform the -v option will not create a window, hence it cannot be minimized or moved. -b - To start QUEST in the batch mode and immediately invoke a BCL file. -s - To launch QUEST in the socket mode to allow communication with other processes on the computer or network. -w (Window) - To run QUEST in a user-sized window in a specified location on the screen. This option includes full borders which allows the window to be sized, moved, and iconized. It is specified by the four parameters following the -w option, which are floating point numbers in the range [0.0 ... 1.0]. -L - Launches QUEST with the specified license number. CONFIGS/Configname - Adding the library configuration file name of a particular project will immediately append the relevant project upon launching QUEST. Although this is a valid startup option, it is advisable to append all required library configuration files through the .qpthfig file. Path to .qpthfig file - This forces QUEST to use this particular .qpthfig instead of looking for one in the user's home directory.

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II.7.1.3. Configuration Files The configuration file (config file) mechanism controls the information that QUEST uses when it loads up and it controls how QUEST uses data for reading and writing. It provides a flexible way to organize data and re-use data in different models. It also provides an easy mechanism for moving models from one computer to another. QUEST stores all of its model-related data in a set of directories known as the Configuration Library. For example, geometries used in the model are stored in the PARTS directory, kinematics are stored in the KINEMATICS directory and so on. This method of storing data in different directories permits re-usability of data in different models. The location of the configuration library (and all its sub-directories) is stored in a file called the Library Configuration File or configs file. A configs file is thus an ASCII text file that contains a series of configs file directory specifications. The syntax of a configs file directory specification is: SYNTAX: $LIB = EXAMPLE: KINEMATICS$LIB = C:\DELMIA\QUESTlib\KINEMATICS PART$LIB = /usr/ DELMIA/QUESTlib/PARTS

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When a configuration file is read by QUEST, the configs file directory specifications are made available to QUEST. This is how QUEST knows where to look for each type of data that it needs, e.g., model files, logic files, default geometries, etc. It is advisable not to store any of your models in the default QUEST1ib or quest directories. These should be write-protected and read-only since any modification to these folders will change the default behavior of QUEST. NOTE: When you start a new simulation project with QUEST it is always a good idea to create a separate library for that project and save all of the project related information there. Apart from the library configuration files mentioned above, there are three special types of configs files that may be created and used with QUEST. They are: 

.qpthfig - This is the QUEST Path Configuration file and is accessed through File Edit Config File. This is where you define a CONFIG$LIB that points to a specific directory on your computer where all your QUEST library configuration files are stored. You may also include specific configs files in the .qpthfig so that these libraries are automatically appended when QUEST is launched. Example .qpthfig file: CONFIG$LIB = c: /Projects/MyQuestConfigs/ Include quest Include Proj ectA. cfg Include AgvProj ect. Cfg

NOTE: When you include specific config files (as done above) it is assumed to be in the SAME directory as specified in the CONFIG$LIB In the above example, the library configuration files named ProjectA.cfg and AgvProject.cfg are assumed to lie in the directory c:/Projects/MyQuestConfigs/.  Rezza Prayogi

.qenvfig - This is the QUEST environment configuration file and is accessed 2-30

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through File Edit Config File. This is where all your QUEST environment specific preferences are stored. The QUEST environment includes settings such as cursor style, floor color, background color, grid size, font size, etc. This file is created when File Save Config File is selected. All the current preferences will be stored and used every time QUEST is launched subsequently. .qbutfig - This is the QUEST button configuration file and is created when you select User Save. This is where the user button information is saved.

None of the three configuration files described are shipped with QUEST and the user must create them. They should be located in your home directory. The simplest method of determining the home directory is to allow QUEST to figure it out by editing/creating these files inside QUEST (use the File Edit Config File option and select the "Write" button to save the file when done). II.7.1.4. The User Interface The user interface is designed to allow you to navigate within the product with the minimum number of keystrokes, while providing an easy-to-use and consistent approach. Shown below is the screen you are presented with when you first start QUEST (on Windows).

Figure II.14. Delmia Quest user interface The user interface is split into five general areas on the screen as shown above. Models themselves are shown in the middle part of the screen. The menus (or contexts on Unix) at the top of the screen connect you to the broad areas of functionality in QUEST. These are defined in detail in the chapters ahead, but they are summarized here as an introduction. The pages on the right of your screen are displayed according to the menu item you choose. These pages in turn contain a group of action buttons that provide specific functions in the product. Note that in the following discussions the terms menu and context, menu items and pages are used interchangeably, but refer to the same function. Rezza Prayogi

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The world controls give you the functionality to manipulate and move around the world (Model, CAD or Draw) that you are currently working with.

II.7.1.5. Pull Down Menu (Context Button) There are ten menus (contexts) in QUEST. Selecting one will activate a pulldown menu, showing a series of items (on Unix, buttons are shown on the right hand side) and are invoked by clicking on the relevant item. For example, selecting the Model menu will show a number of items such as Build, MHS, Layout, etc. On Unix systems, this user interface is known as the three-tier interface. The menus cover the following areas: File The file menu has file handling functions including loading and saving models (with the same name or different name), creating and appending libraries, and generally manipulating files. Model This is the main model development menu that permits element and class creation, connections, 2D modeling, and process creation. Advanced This menu includes auxiliary model building menu that permits creation and manipulation of groups, popups, kinematics, and display settings. Run Run provides a number of controls to run and debug the simulation, and analyze the performance of the system by gathering various statistics and reports. CAD CAD is used to import, create or modify the geometrical representations of the logical elements in the model. QUEST provides a set of data translators so that layouts and components may be imported from other 2D or 3D CAD software packages. Draw Draw is used for the creation or modification of 2D geometries. Tools The Tools menu provides a series of functions including dimensioning, measuring, and lighting. The items on the Tools page are dependent on context that was invoked before the Tools context was invoked. The Windows functionality is located under the Tools menu. User The User menu provides a series of user pages that you can customize. The user pages provide two distinct options for customization. User buttons permit the duplication of any other button in the interface. This is very useful when you have a limited number of functions that you use very often, but they are spread over a number of different pages. These buttons may be collected and placed together on a user page for quicker access. User buttons can also invoke SCL or BCL macros. Pref

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Pref allows you to setup preferences such as color, button style, grid size, and level of detail. This menu thus provides options to change the look and feel of QUEST. Help The help menu allows you to access the QUEST online help documentation and the button help. It also lets you determine the current QUEST version, license number, options installed, and current user information. II.7.1.6. World Control Button The World Control Buttons shown below provide a combination of dialog boxes and functionality to manipulate the way in which the current world (Model, CAD, or Draw) is displayed. This functionality is summarized below.

Figure II.15. World Control Button Light QUEST provides a number of lights that can be positioned and turned on to provide enhanced reality and shadowing effects. The Lights page allows the manipulation of the position of these light sources. After clicking on the Lights button you can then move the mouse with either the left or middle mouse buttons held down to change the angle and elevation of the light source relative to the current center of interest. This button works only when Pref Shadow button is toggled on. Camera Clicking on the Camera button invokes the Camera Options dialog box and resulting dialog boxes as shown below.

Figure II.16. Camera dialog box

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Camera Specs - This selection allows you to set the projection type (orthographic or perspective), the image plane size, focal length and the field of view. It controls the perception of distance while looking at the model.

 Tracking - This selection allows you to set the center of view onto a part or frame. As you run the simulation the part or frame will be maintained at the center of view. This is particularly useful when you want to follow a particular part as it moves through a model. The Cruise or Rotate world display buttons may not be used when tracking is switched on.  Mounting - This selection allows you to mount the camera on a part, frame (coorsys), or surface. Once selected, the camera is snapped to the relevant place and moves with the entity to which it is now attached. The "Grab by Part" selection causes the camera to be mounted in its current position relative to the selected part, and as that part moves the camera will move to maintain the same position relative to the part.  Pan/Tilt - This selection gives you the ability to pan/tilt the camera using the right mouse button (RMB) and to change the field of view using the middle mouse button (MMB). Clicking on a specific point in the model with the RMB immediately selects that point as the center of interest (COI).  Locate - This selection allows you to translate the camera within the field of view. Invoking the Fly world display button creates a small box at the center of view. Dragging the mouse with the left mouse button (LMB) held down will cause an acceleration towards the center of view. The same action with the RMB will move you away from the center of view. Use the MMB to aim the view point in any direction. Rotate Invoking the Rotate world display button and moving the mouse with one of the left/middle/right buttons pressed, will rotate the view around the center of the model. You can also type rotations directly using the Reset and Abs buttons or snap the rotation by 90 degrees in each direction with the Snap button. Cruise The cruise feature is the most commonly used tool for moving around the world. If you move the mouse with the LMB held down, QUEST will rotate the camera about the current center of interest (COI). Using the MMB will translate the camera directly towards or away from the COI, this allows you to zoom in on a particular feature of interest very quickly. The RMB provides two functions: If you hold down the RMB and move the mouse, QUEST will trace a circle around the area of interest, as you release the RMB the camera will zoom towards the selected area. If you click on a specific point with the RMB, QUEST will select that point as the COI. View The View button provides a series of dialog boxes shown below, to create and retrieve a set of standard camera positions for a model. The standard views list box provides set views of the model based on the current center of interest. These are useful, especially when you are operating with the camera in orthographic mode, for positioning elements in a model.

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Figure II.17. User View dialog box 

Standard Views - This selection allows you to quickly set the view to one of six system-provided standard views.

 User Views / User View Utilities - This selection allows you to create your own views of the model. The User View Utilities allows you to save the current view and invoking User Views will show all the user views that you have saved so far. This combination is used when you wish to create a choreographed walk through of a model either for presentations or for digital output such as videos or AVIs.  Display States / Display States Utilities - Allows you to capture the general display conditions of a model at a particular time. Selecting Display States presents a list of the display states that have been set up.  Find Element - Allows you to locate a lost element in the world; which would usually happen when the model happens to be a big one. This functionality prompts the user to first select an element that they are looking for. The selected element is then centered and magnified. The hither plane will also be adjusted. The element will remain highlighted while the camera moves in on the element. The number of steps is controlled by selecting the Environment I Input button and changing the "Max Magnify Steps". All other elements are made transparent at the end of the camera move. You may still be required to do some cruising to fully see the selected element. However, the element will be made the center of interest, so further zooming should bring the element into view. If you select an element with no geometry, like a path system, then a message will be issued. Display The Display button, in the Model world, invokes the World Display Mode dialog box as shown below.

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Figure II.18. Display dialog box 

Render - This sets the render properties for all elements and parts in a model. This will override the individual settings on parts or elements. The options are default, flat, smooth, wire, and transparent. Setting the render to smooth will result in a higher quality view, but requires more system resources. Wire converts everything to wireframe mode, while transparent turns all elements to transparent (that is, it will create a see-through effect for all geometries).



The remaining selections turn the associated function on or off. Further discussion of the World Display Mode dialog box is provided in Appendix A, The QUEST User Interface.

Modes The Modes world display button brings up the Model Modes dialog box shown below and provides a series of options.

Figure II.19. Modes dialog box 

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Multi Views - Allows you to split the screen into a number of views of the same model. This is a powerful function in both the CAD and modelling worlds. In CAD it can be very useful when you are working from 2D drawings, for example DXF. In this case you can split the views into plan and

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elevation views to build up the 3D view. In the modeling world, split views are useful when you need to look at a number of parts of your model at the same time. You can cruise in each of the views independently.  Stacking Mode - This determines whether one or all of the parts in a buffer will be visible.  Entity List Order - This defines the order in which the names of Via Points appear in any entity selection dialog box for all Via Point selection options.  Indicate Point - This defines the type of point picking when indicating points. II.7.1.7. Using the Mouse A three-button mouse is required for using QUEST. By now you should be able to start QUEST and move through the general functions of the product. The three mouse buttons are a vital part of the user interface and contribute significantly to the ease of use of the product. See Appendix A, The QUEST User Interface for more information on entity selection, zip mode, and point indication with using the mouse. Translating or Rotating Elements The left, middle, and right mouse buttons (LMB, MMB, RMB) are often linked to the x, y, or z axis respectively. This works when you are manipulating an element or CAD part, either using the Trn (translate) or Rot (rotate) buttons. In either case once the button is selected, moving the mouse with the respective mouse button held down will move or rotate the chosen element in one direction. If you select the Tmn or Rot buttons with the RMB then the world will move to wireframe for the duration of the function. This allows items to be manipulated more quickly. ZIP Mode Zip mode is the process of selecting a function with the RMB. Many functions have intermediate steps. Using zip mode will skip intermediate functions where appropriate, generally assuming that the intermediate steps are a repeat of a previous invocation. For example: If the Run button is selected with the RMB, then the run begins immediately using previously entered values for the Run Time dialog box. Zip mode reduces the number of keystrokes. It is advisable not to use the zip mode until you become familiar with QUEST.

II.7.2. Step by Step to Build Delmia Simulation Introduction This sub-chapter will introduce the basic modelling constructs used to develop a QUEST simulation model. In this sub-chapter, the concepts of a part class and element class are used to build a simple straight-through processing system. A part class can be defined to create a number of parts having the same properties. A part is an entity that moves between elements and is processed by the system. Parts are generated at sources or as a result of a machine process. Parts are consumed by sinks or as a result of a machine process. Similarly, an element class can be defined to create a number of elements having the same properties. Elements are the basis of how QUEST models systems.

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Different types of elements include AGVs, AGV path systems, buffers, controllers, conveyors, labor, power and free path systems, sources, sinks, and machines. Displaying QUEST Once QUEST is "launched", the QUEST window and QUEST 3D window will use only about two-thirds of the screen. The 3D window is used for the threedimensional graphics simulation. For best visual results, expand the QUEST Window and the 3D window to fill the screen. Messages The user is strongly encouraged to monitor the messages appearing in the message window at every step throughout this step by step example. These messages will confirm actions completed, prompt the user for additional action, or prompt the user that an action is unsuccessful. Set Up 1. Select the maximize button at the top right-hand corner to enlarge the QUEST window. Select the same button in the QUEST 3D window to maximize the work area window.

Figure II.20. Set up the window 2.

Figure II.21. Question to clear world from previous simulation If QUEST was used previous to starting this model building session, the QUEST world should be cleared and reset. To do this, select File | Clear World. When prompted with ? Clear World ?, select Yes to confirm this selection. 3. While QUEST is clearing the system, the message window will display "Reinitializing the System ..." When this is finished, the message window will display "World cleared". 4. The next step is to Reset the world. Select File | Reset World. When prompted with ?Reset World?, select Yes to confirm the selection.

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5.

Figure II.22. Change simulation time units The proper time units need to be set. To do this, select Run | Simulate | Time Units. Complete the Time Units dialog box as shown and click on OK. 6.

Figure II.23. Change unit The proper distance units need to be set. To do this, select Tools | Measure | Units. Choose the appropriate units as shown and click on OK.

Create a Part Class A part class to be used in this model can be created. Select Model | Build | Part Class | Create/Modify. Use the default settings in the Part Class dialog box and click on OK.

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Figure II.24. Part dialog box

Figure II.25. Sample Model with Elements

Create a Source One source, which is an element as previously mentioned, will be created for this model to serve as a mechanism by which the parts can enter the model. 1. Select Model | Build | Element Class | Source. The Source dialog box will appear.

Figure II.26. Source dialog box

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To define the inter-arrival time for the source, select the IAT button. Choose Exponential from the Distributions list and click on OK. In the Exponential dialog box, change the Mean to 25, and the Starting Stream to 1. Click on OK to close this dialog box and click on OK in the Source dialog box. The message window now displays "Element Created. Select a location on the floor/2D window for ."

NOTE: Source1 is the name of the class, while Source1_1 is the name of one source which belongs to class Source1. In this particular step by step example only, one source belonging to class Source1 will be created. Any number of sources belonging to this class could be created if desired. In general, the only properties that are different between multiple elements of the same class are their names, location, and connections. 2. See Figure II.25 for the positions of the various model elements to be created in this model. Use the world display buttons at the bottom of the screen (Rotate, Cruise, View, etc.) to reorient the screen view in order to get an overall picture of the working grid. Use the LMB and click on the approximate location where the source should be positioned. 3. Select Model | Build | Element | Trn. Using the LMB, move the currently selected Source1_1 across the grid along the X axis or, with the MMB, move along the Y axis until Source1_1 is properly located. It is more important to place all the elements in a specific relationship to one another rather than placing them in absolute locations. If necessary, elements can be moved at a later time. Create a Machine Parts are created at the source and are processed on a machine. This machine will be created next. 1. Select Model | Build | Element Class | Machine. The Machine dialog box will appear.

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Figure II.27. Machine dialog box Select the Cycle Process button to further define this machine. 2. Choose New Process in the Select Process dialog box. The Cycle Process Definition dialog box will be displayed. Select the Cycle Time button.

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Figure II.28. Cycle process dialog box 3. Choose Normal distribution and click on OK. Enter a Mean of 25 and a Standard Deviation of 5 secs. To maintain statistical independence set the Starting Stream Value to 2 and click on OK. Click on OK on the Cycle Process Definition dialog box. Click OK on the Machine dialog box. The message window will display:

Figure II.29. Message to put Machine on the Floor As before, Machine1 is the name of the class, while Machine1_1 is the name of a machine which is of the class Machine1. In this step by step example, only one machine will be created; however, any number of machines could be created in the class if necessary. 4. Select a location on the floor/2D window for Machine1_1. See Figure II.25 to see where to place Machine1_1 in relationship to Source1_1. Its position can be corrected later if necessary.

Create a Sink

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A sink will be created to collect the processed parts for their exit from the model. 1. Select Model | Build | Element Class | Sink. Leave the default settings on the Sink dialog box and click on OK.

Figure II.30. Sink dialog box 2. One sink will be created named Sink1_1 as the first sink of class Sink1. Position Sink1_1 as shown in Figure II.25.

Create Buffers Two buffers will be created for this model: one between Source1_1 and Machine1_1, and another between Machine1_1 and Sink1_1. 1. Select Model | Build | Element Class | Buffer. In the Buffer dialog box, change the No. of Elements to 2 and leave all other values as is. Select the Display button. Set the Color to any available value. In this instance, Brown was chosen. Click on OK in the Display and Buffer dialog boxes. Because the Display definition is for the Buffer1 class, both buffers will be brown.

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Figure II.31. Buffer dialog box 2. When prompted, position Buffer1_1 between Source1_1 and Machine1_1. Position Buffer1_2 between Machine1_1 and Sink1_1. Use the Locate button or the Sel | Trn to move any of the elements until they are in the proper relationship as shown in Figure II.25. Connect the Elements With the basic process elements defined, the sequence of processes can be defined to assure the proper flow of parts through the system. Connections are required between each element to make this happen. 1. Select Model | Build | Connections | Element. The message window will prompt for a starting element. With the LMB, pick Source1_1. When prompted, pick Buffer1_1 as the ending element. This completes the first connection. 2. The message window will prompt for the starting point of the next connection. Pick Buffer1_1, again, and when prompted to indicate the ending element, pick Machine1_1. To complete the third connection, when prompted, pick Machine1_1 as the starting element and pick Buffer1_2 as the ending element. The last connection is to select Buffer1_2 as the starting element and Sink1_1 as the ending element. Note that the dialog boxes, Select an Output Element, and Select an Input Element have not been used. To remove the final Select an Output Element dialog box, click on Cancel in the dialog box.

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If necessary, select the Model | Build | Connections | Show button and proceed through the message window prompts to check the connections. A window will appear showing the input and/or output of the selected element. Save the Model It is good practice to save the model throughout any model building process. There are two ways to do this. 1. Select File | Save Model or File | Save Model As and save the model as basic01.mdl in c:\deneb\QTUTORlib\MODELS Or, 2. Select Model | Build | Model | Save and save the model as basic01.mdl in c:\deneb\QTUTORlib\MODELS Run the Simulation 1. To run the simulation, select Run | Simulate | Simulation | Run. Enter the values as shown below, and click on OK. The simulation will run for 1000 seconds.

Figure II.32. Run simulation dialog box

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CHAPTER III PROJECT AND CALCULATION III.1. Introduction The purpose of this chapter is to illustrate the systematic approach presented in this master thesis for the design of a manufacturing facility using digital factory. The project is broken into several segments, which presented in the proper sequence. Each project segment utilizes the concepts, tools, and the various topics that are set close to the theory presented in chapter 2 and will lead toward the design of a complete manufacturing facility for the fabrication and assembly of a gas grill product. The fictitious Gas Grill serves as a practical example of how to follow the approach and apply the material and the tools covered in theory chapter 2 for the design of an effective and an efficient manufacturing facility. The beauty of facilities design lies in the fact that whereas an array of qualitative and quantitative tools are available, and the design can be subjected and evaluated through the use of numerous analytical means, there remains a significant latitude to accommodate the planners creativity and vision. It is, therefore, quite conceivable and even expected that different teams of facilities planners would arrive at completely different designs for the production of the same products. Individual differences, philosophies, visions, creativity, and even compromises will result in variations in designs of the facility. These differences do not necessarily affect the main objectives of the facility or adversely influences its functionality and productivity, but simply result in varied and different outcomes in the design. Without a doubt, some plant layouts are better than others. They adhere to all the goals of the manufacturing facilities design, procedures for reduction of waste, and the principles and practices of lean manufacturing. Of course, there are those that leave a lot to be desired and provide the greatest opportunity for improvements. I collect all data from Moryl GmbH where I make my internship for 8 month; I collect data for machines, scrap rates, manufacturing time, material movement time, time standards and a lot of historical data. This data are vital in determining equipment and personnel requirements, balancing assembly lines, setting conveyor belt speeds, estimating product cost, and so on.

III.2. Design of Gas Grill In this sub-chapter, I will present the design of gas grill. As stated by theory, a new facility should be started with a product that wants to be produce. This subchapter usually created by Design Engineer Department, data for a new product (or improved product) comes from marketing, sales, customer service departments, because those department have an accurate data from our targeted customer. With the aid of the various departments such as engineering, fabrication, purchasing, the exploded view of the grill, the indented bill of materials, manufactured purchased parts drawing and specifications are developed and here presented. Scrap rate are obtained for various processes and departments based on their historical data and sources of information.

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Figure III.1 Gas grill in 3D CAD view which created using Solidworks

Figure III.2 Gas grill in rendered view which created using Photoworks

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Figure III.3. Exploded view of my gas grill (for assembly purpose)

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Table III.1 Indented Bill of Material from my gas grill Level Part No. Part Name Drwg. No. 0 STG1 Packaged grill DWG1 1 PP1 Bottom grill casting PDWG1 1 PP2 Grease can wire PDWG2 1 PP3 Top grill casting PDWG3 1 PP4 Wood handle PDWG4 1 STG4 Legs DWG4 2 STG8 Top support DWG8 1 STG5 Tube plugs DWG5 1 STG6 Leg extensions DWG6 1 STG7 Wood slats DWG7 1 STG9 Bottom support DWG9 1 STG10 Tank holder DWG10 1 STG11 Axle DWG11 1 PP11 Wheels PDWG11 1 PP12 Hub caps PDWG12 1 STG12 Control panel DWG12 1 STG13 Knob DWG13 1 PP13 Ignitor PDWG13 1 PP14 Valve assembly PDWG14 1 PP15 Burner element PDWG15 1 PP16 Cooking grid PDWG16 1 PP17 Rock grate PDWG17 1 PP19 Heat shield PDWG19 1 PP20 Accessories bag PDWG20 2 PP5 10-24 x 1/2” bolts PDWG5 2 PP6 10-24 nuts PDWG6 2 PP7 Washer PDWG7 2 PP8 10-24 x 1 3/8” screws PDWG8 2 PP9 #6-32 x 3/8” bolt PDWG9 2 PP10 Cotter pin PDWG10 2 PP105 Pin PDWG105

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Qty/Unit 1 1 1 1 1 4 2 4 2 4 2 1 1 2 2 1 1 1 1 1 1 1 1 1 12 3 1 13 2 2 2

Make/Buy M B B B B M M M M M M M M B B M M B B B B B B B B B B B B B B

III.3. Takt Time and Scrap Rates Calculation In this sub-chapter, I calculate for takt time (R Value) or plant rate and scrap rates for later use in manufacturing design and simulation. In this factory I will use 3 shifts with each shift include 8 hour working time. 8 hour shift × 60 minutes = 480 minutes 480 minutes - 30 minutes lunch - 10 minutes 1st break - 10 minutes 2nd break 430 minutes total available (per shift) 430 minutes × 3 shifts = 1.290 minutes/day Rezza Prayogi

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Assuming 75% plant efficiency: 1.290 minutes/day × 75% = 967,5 minutes/day When we want to produce 1.500 grills per day: 967, 5 minutes/day ÷ 1.500 grills/day = 0,645 minutes/grill From Table III.1, we just want to make 10 parts and for 1.500 gas grill/day, we need: 1. Legs : 1.500 × 4 = 6.000 legs/day 2. Wood slats : 1.500 grill/day × 5 = 7.500 wood slats/day For wood slats actually 4 part per grill, but 1 wood for customer bonus extra, when the wood is broken or burned in used. 3. Control panel : 1.500 grill/day × 1 = 1.500 control panel/day 4. Top support : 1.500 grill/day × 2 = 3.000 top support/day 5. Bottom Support : 1.500 grill/day × 2 = 3.000 bottom support/day 6. Tube plugs : 1.500 grill/day × 4 = 6.000 tube plugs/day 7. Knob : 1.500 grill/day × 1 = 1.500 knob/day 8. Leg extensions : 1.500 grill/day × 2 = 3.000 leg extensions/day 9. Tank holder : 1.500 grill/day × 1 = 1.500 tank holder/day 10. Axle : 1.500 grill/day × 1 = 1.500 axle/day Table III.2 Operation Scrap Rates – courtesy of Moryl GmbH Operation Name Percent of scrap Cutting 1% + 1 parts need Drilling 0,25% Shearing 0,5 % Stamping 0,25% Bending Welding Deburring 0,5 % Sanding 0,5 % Painting Assembling Inspecting Packaging Trimming 0,1% Molding 1% From Table III.2 we can calculate scraps for each part that will be produce in our factory, as calculated follow (see the results at Table III.3). 1. Legs→ Cutting: (6.000 × 1%) + 1 = 61 Drilling: 6.000 × 0,25% = 15 Bending: 6.000 × 0% =0 Deburring: 6.000 × 0,5% = 30 Welding: 6.000 × 0% =0 Painting: 6.000 × 0% =0 ____________________________________+ Total scrap = 106 Parts needed/day = 6.106

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2. Wood slats → Cutting: (7.500 × 1%) + 1 = 76 Drilling: 7.500 × 0,25% = 18,75 Sanding: 7.500 × 0,5% = 37,5 ____________________________________+ Total scrap = 132,25 ~ 133 round up Parts needed/day = 7.633 3. Control Panel → Shearing: 1.500 × 0,5% = 7,5 Stamping: 1.500 × 0,25% = 3,75 Bending: 1.500 × 0 % = 0 Deburring: 1.500 × 0,5% = 7,5 __________________________________+ Total scrap = 18,75 ~ 19 round up Parts needed/day = 1.519 4. Top support → Shearing: 3.000 × 0,5% = 15 Stamping: 3.000 × 0,25% = 7,5 Bending: 3.000 × 0 % =0 ___________________________________+ Total scrap = 22,5 ~ 23 round up Parts needed/day = 3.023 5. Bottom support → Shearing: 3.000 × 0,5% = 15 Stamping: 3.000 × 0,25% = 7,5 Bending: 3.000 × 0 % =0 Drilling: 3.000 × 0,25% = 7,5 ___________________________________+ Total scrap = 30 + 1 for safety = 31 Parts needed/day = 3.031 6. Tube plugs →

Molding: 6.000 × 1% Parts needed/day

= 60 = 6.060

7. Knob →

Molding: 1.500 × 1% Parts needed/day

= 15 = 1.515

8. Leg extensions → Molding: 3.000 × 1% Parts needed/day

= 30 = 3.030

9. Tank holder →

Shearing: 1.500 × 0,5% = 7,5 Stamping: 1.500 × 0,25% = 3,75 Bending: 1.500 × 0% =0 Drilling: 1.500 × 0,25% = 3,75 ______________________________________+ Total scrap = 15 + 1 for safety = 16 Parts needed/day = 1.516

10. Axle →

Cutting: (1.500 × 1%) + 1 Parts needed/day

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Table III.3 Scrap Rates Part No. Part Name

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Quantity/ day

STG4

Legs

6.000

STG7

Wood slats

7.500

STG12

Control Panel

1.500

STG8

Top support

3.000

STG9

Bottom support

3.000

STG5 STG13 STG6

Tube plugs Knob Leg extensions

6.000 1.500 3.000

STG10

Tank holder

1.500

STG11

Axle

1.500

Operations Needed Cutting Drilling Bending Deburring Welding Painting Cutting Drilling Sanding Shearing Stamping Bending Deburring Shearing Stamping Bending Shearing Stamping Bending Drilling Molding Molding Molding Shearing Stamping Bending Drilling Cutting

Calculated Scrap

Parts/ Day

106

6.106

133

7.633

19

1.519

23

3.023

31

3.031

60 15 30

6060 1.515 3.030

16

1.516

16

1.516

III.4. Process Design This sub-chapter will be talking about process design procedures and tools included route sheets, machine requirements spreadsheets, work cell layouts, work cell load charts, assembly charts, assembly line balancing forms, and so on. Every fabricated (manufactured) part requires a completed route sheet. To complete these route sheets, the industrial engineering department at Moryl GmbH has been provided time study data, including standard time for operation. The manufacturing and process engineers at Moryl GmbH provide data regarding the specific processes so I can choose types of equipment needed. The machine requirements spreadsheet summarizes fabrication equipment requirements. With the aid of the assembly chart, assembly lines are identified and balanced to maximize line efficiency and meet the required takt time or R value. III.4.1. Cycle Time and Fraction Equipment The First is calculation of cycle time, fraction equipment, piece/hours, hour/pieces; this should be used time standard as their base, and this time standard

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come from time study conduct by Industrial Engineering, using method like stopwatch time study, work sampling, predetermined time standard system, standard data, expert opinion based on standard and historical data. But this time I don’t have a team to conduct this statistical time study, so I use Expert Opinion (assumption) from Industrial Engineering team at Moryl GmbH. Cycle time is the time standard set by combining elements of works together into jobs. 1. Axle a. Cutting i. Cycle time = 0,165 min/piece ii. Fraction equipment = cycle time ÷ takt time = 0,165÷0,645 = 0,256 iii. Pieces/hour = 60 min/hour ÷ 0,165 min/pieces = 363,64 iv. Hours/piece = 1÷ 363,64 pieces/hour = 0,00275 v. Hours/1000 = 1000 × 0,00275 = 2,75 2. Tube Plugs a. Molding i. Cycle time = 0,0625 min/piece ii. Fraction equipment = 0,0625min/piece ÷ 0,645min/grill= 0,097 iii. Pieces/hour = 60 min/hour ÷ 0,00625 min/piece = 960 iv. Hours/piece = 1 ÷ 960 pieces/hour = 0,00104 v. Hours/1000 = 1000 × 0,00104 = 1,042 b. Trimming i. Cycle time = 0,073 min/piece ii. Fraction equipment = 0,073min/piece ÷ 0,645 min/grill = 0,113 iii. Pieces/hour = 60 min/hour ÷ 0,073 min/piece = 832,918 iv. Hours/piece = 1 ÷ 832,918 pieces/hour = 0,00122 v. Hours/1000 = 1000 × 0,00122 = 1,217 3. Leg Extensions a. Molding i. Cycle time = 0,125 min/piece ii. Fraction equipment = 0,125min/piece ÷ 0,645 min/grill= 0,194 iii. Pieces/hour = 60 min/hour ÷ 0,125 min/piece = 480 iv. Hours/piece = 1 ÷ 480 pieces/hour = 0,00208 v. Hours/1000 = 1000 × 0,00208 = 2,08 b. Trimming i. Cycle time = 0,042 min/piece ii. Fraction equipment = 0,042min/piece ÷ 0,645 min/grill = 0,065 iii. Pieces/hour = 60 min/hour ÷ 0,073 min/piece = 1428,571 iv. Hours/piece = 1 ÷ 1428,571 pieces/hour = 0,0007 v. Hours/1000 = 1000 × 0,0007 = 0,7 4. Top Support a. Shearing i. Cycle time = 0,033 min/piece ii. Fraction equipment = 0,033min/piece ÷ 0,645 min/grill = 0,051 iii. Pieces/hour = 60 min/hour ÷ 0,033 min/piece = 1818,182 iv. Hours/piece = 1 ÷ 1818,182 pieces/hour = 0,00055

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v. Hours/1000 = 1000 × 0,00055 = 0,55 b. Stamping i. Cycle time = 0,033 min/piece ii. Fraction equipment = 0,033min/piece ÷ 0,645 min/grill = 0,051 iii. Pieces/hour = 60 min/hour ÷ 0,033 min/piece = 1818,182 iv. Hours/piece = 1 ÷ 1818,182 pieces/hour = 0,00055 v. Hours/1000 = 1000 × 0,00055 = 0,55 c. Bending i. Cycle time = 0,033 min/piece ii. Fraction equipment = 0,033min/piece ÷ 0,645 min/grill = 0,051 iii. Pieces/hour = 60 min/hour ÷ 0,033 min/piece = 1818,182 iv. Hours/piece = 1 ÷ 1818,182 pieces/hour = 0,00055 v. Hours/1000 = 1000 × 0,00055 = 0,55 d. Painting i. Cycle time = 60 min/piece ii. Fraction equipment = 60min/piece ÷ 0,645 min/grill = 93,023 iii. Pieces/hour = 60 min/hour ÷ 60min/piece = 1 iv. Hours/piece = 1 ÷ 1 pieces/hour = 1 v. Hours/1000 = 1000 × 1 = 1000 5. Bottom Support a. Shearing i. Cycle time = 0,033 min/piece ii. Fraction equipment = 0,033min/piece ÷ 0,645 min/grill = 0,051 iii. Pieces/hour = 60 min/hour ÷ 0,033 min/piece = 1818,182 iv. Hours/piece = 1 ÷ 1818,182 pieces/hour = 0,00055 v. Hours/1000 = 1000 × 0,00055 = 0,55 b. Stamping i. Cycle time = 0,033 min/piece ii. Fraction equipment = 0,033min/piece ÷ 0,645 min/grill = 0,051 iii. Pieces/hours = 60 min/hour ÷ 0,033 min/piece = 1818,182 iv. Hours/piece = 1 ÷ 1818,182 pieces/hour = 0,00055 v. Hours/1000 = 1000 × 0,00055 = 0,55 c. Bending i. Cycle time = 0,033 min/piece ii. Fraction equipment = 0,033min/piece ÷ 0,645 min/grill = 0,051 iii. Pieces/hour = 60 min/hour ÷ 0,033 min/piece = 1818,182 iv. Hours/piece = 1 ÷ 1818,182 pieces/hour = 0,00055 v. Hours/1000 = 1000 × 0,00055 = 0,55 d. Drilling i. Cycle time = 0,246 min/piece ii. Fraction equipment = 0,246min/piece ÷ 0,645 min/grill = 0,381 iii. Pieces/hour = 60min/hour ÷ 0,246 min/piece = 243,902 iv. Hours/piece = 1 ÷ 243,902 pieces/hour = 0,0041 v. Hours/1000 = 1000 × 0,0041 = 4,1 e. Painting i. Cycle time = 60 min/piece ii. Fraction equipment = 60min/piece ÷ 0,645 min/grill = 93,023 iii. Pieces/hour = 60 min/hour ÷ 60min/piece = 1 iv. Hours/piece = 1 ÷ 1 piece/hour = 1

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3-9

Facilities Planning using Digital Factory

Master Thesis

v. Hours/1000 = 1000 × 1 = 1000 6. Wood Slats a. Cutting i. Cycle time = 0,165 min/piece ii. Fraction Equipment = 0,165 min/piece ÷ 0,645min/grill = 0,256 iii. Pieces/hour = 60 min/hour ÷ 0,165 min/piece = 363,636 iv. Hours/piece = 1 ÷ 363,636 pieces/hour = 0,00275 v. Hours/1000 = 1000 × 0,00275 = 2,75 b. Drilling i. Cycle time = 0,123 min/piece ii. Fraction Equipment = 0,123min/piece ÷ 0,645 min/grill = 0,191 iii. Pieces/hour = 60 min/hour ÷ 0,123 min/piece = 487,805 iv. Hours/piece = 1÷ 487,805 pieces/hour = 0,00205 v. Hours/1000 = 1000 × 0,00205 = 2,05 c. Sanding i. Cycle time = 0,167 min/piece ii. Fraction Equipment = 0,167min/piece ÷ 0,645 min/grill = 0,259 iii. Pieces/hour = 60 min/hour ÷ 0,167 min/piece = 359,281 iv. Hours/piece = 1÷ 359,281 pieces/hour = 0,00278 v. Hours/1000 = 1000 × 0,00278 = 2,783 7. Tank Holder a. Shearing i. Cycle time = 0,033 min/piece ii. Fraction equipment = 0,033min/piece ÷ 0,645 min/grill = 0,051 iii. Pieces/hour = 60 min/hour ÷ 0,033 min/piece = 1818,182 iv. Hours/piece = 1 ÷ 1818,182 pieces/hour = 0,00055 v. Hours/1000 = 1000 × 0,00055 = 0,55 b. Stamping i. Cycle time = 0,033 min/piece ii. Fraction equipment = 0,033min/piece ÷ 0,645 min/grill = 0,051 iii. Pieces/hour = 60 min/hour ÷ 0,033 min/piece = 1818,182 iv. Hours/piece = 1 ÷ 1818,182 pieces/hour = 0,00055 v. Hours/1000 = 1000 × 0,00055 = 0,55 c. Bending i. Cycle time = 0,033 min/piece ii. Fraction equipment = 0,033min/piece ÷ 0,645 min/grill = 0,051 iii. Pieces/hour = 60 min/hour ÷ 0,033 min/piece = 1818,182 iv. Hours/piece = 1 ÷ 1818,182 pieces/hour = 0,00055 v. Hours/1000 = 1000 × 0,00055 = 0,55 d. Drilling i. Cycle time = 0,246 min/piece ii. Fraction equipment = 0,246min/piece ÷ 0,645 min/grill = 0,381 iii. Pieces/hour = 60min/hour ÷ 0,246 min/piece = 243,902 iv. Hours/piece = 1 ÷ 243,902 pieces/hour = 0,0041 v. Hours/1000 = 1000 × 0,0041 = 4,1

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3-10

Facilities Planning using Digital Factory

Master Thesis

8. Knob a. Molding i. Cycle time = 0,125 min/piece ii. Fraction equipment = 0,125min/piece ÷ 0,645 min/grill= 0,194 iii. Pieces/hour = 60 min/hour ÷ 0,125 min/piece = 480 iv. Hours/piece = 1 ÷ 480 pieces/hour = 0,00208 v. Hours/1000 = 1000 × 0,00208 = 2,08 b. Trimming i. Cycle time = 0,06 min/piece ii. Fraction Equipment = 0,06 min/piece ÷ 0,645 min/grill = 0,093 iii. Pieces/hour = 60 min/hour ÷ 0,06 min/piece = 1000 iv. Hours/piece = 1 ÷ 1000 = 0,001 v. Hours/1000 = 1000 × 0,001 = 1 9. Legs a. Cutting i. Cycle time = 0,033 min/piece ii. Fraction equipment = 0,033min/piece ÷ 0,645 min/grill = 0,051 iii. Pieces/hour = 60 min/hour ÷ 0,033 min/piece = 1818,182 iv. Hours/piece = 1 ÷ 1818,182 pieces/hour = 0,00055 v. Hours/1000 = 1000 × 0,00055 = 0,55 b. Drilling i. Cycle time = 0,123 min/piece ii. Fraction Equipment = 0,123min/piece ÷ 0,645 min/grill = 0,191 iii. Pieces/hour = 60 min/hour ÷ 0,123 min/piece = 487,805 iv. Hours/piece = 1÷ 487,805 pieces/hour = 0,00205 v. Hours/1000 = 1000 × 0,00205 = 2,05 c. Bending i. Cycle time = 0,167 min/piece ii. Fraction Equipment = 0,167min/piece ÷ 0,645 min/grill = 0,259 iii. Pieces/hour = 60 min/hour ÷ 0,167 min/piece = 359,281 iv. Hours/piece = 1÷ 359,281 pieces/hour = 0,00278 v. Hours/1000 = 1000 × 0,00278 = 2,783 d. Deburring i. Cycle time = 0,125 min/piece ii. Fraction equipment = 0,125min/piece ÷ 0,645 min/grill= 0,194 iii. Pieces/hour = 60 min/hour ÷ 0,125 min/piece = 480 iv. Hours/piece = 1 ÷ 480 pieces/hour = 0,00208 v. Hours/1000 = 1000 × 0,00208 = 2,08 e. Welding i. Cycle time = 0,5 min/piece ii. Fraction Equipment = 0,5min/piece ÷ 0,645 min/grill = 0,775 iii. Pieces/hour = 60 min/hour ÷ 0,5 min/piece = 120 iv. Hours/piece = 1 ÷ 120 pieces/hour = 0,0083 v. Hours/1000 = 1000 × 8,333 f. Painting i. Cycle time = 60 min/piece ii. Fraction equipment = 60min/piece ÷ 0,645 min/grill = 93,023 iii. Pieces/hour = 60 min/hour ÷ 60min/piece = 1 iv. Hours/piece = 1 ÷ 1 piece/hour = 1

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3-11

Facilities Planning using Digital Factory

Master Thesis

v. Hours/1000 = 1000 × 1 = 1000 10. Control Panel a. Shearing i. Cycle time = 0,033 min/piece ii. Fraction equipment = 0,033min/piece ÷ 0,645 min/grill = 0,051 iii. Pieces/hour = 60 min/hour ÷ 0,033 min/piece = 1818,182 iv. Hours/piece = 1 ÷ 1818,182 pieces/hour = 0,00055 v. Hours/1000 = 1000 × 0,00055 = 0,55 b. Stamping i. Cycle time = 0,099 min/piece ii. Fraction Equipment = 0,099min/piece ÷ 0,645 min/grill = 0,153 iii. Pieces/hour = 60 min/hour ÷ 0,099 min/piece = 606,601 iv. Hours/piece = 1÷ 606,601 pieces/hour = 0,00165 v. Hours/1000 = 1000 × 0,00165 = 1,65 c. Bending i. Cycle time = 0,099 min/piece ii. Fraction Equipment = 0,099min/piece ÷ 0,645 min/grill = 0,153 iii. Pieces/hour = 60 min/hour ÷ 0,099 min/piece = 606,601 iv. Hours/piece = 1÷ 606,601 pieces/hour = 0,00165 v. Hours/1000 = 1000 × 0,00165 = 1,65 d. Deburring i. Cycle time = 0,125 min/piece ii. Fraction equipment = 0,125min/piece ÷ 0,645 min/grill= 0,194 iii. Pieces/hour = 60 min/hour ÷ 0,125 min/piece = 480 iv. Hours/piece = 1 ÷ 480 pieces/hour = 0,00208 v. Hours/1000 = 1000 × 0,00208 = 2,08 e. Painting i. Cycle time = 60 min/piece ii. Fraction equipment = 60min/piece ÷ 0,645 min/grill = 93,023 iii. Pieces/hour = 60 min/hour ÷ 60min/piece = 1 iv. Hours/piece = 1 ÷ 1 piece/hour = 1 v. Hours/1000 = 1000 × 1 = 1000 The result of above calculation is presented in following route sheet table, including cycle time, fraction equipment, pieces/hour, hours/piece, hours/1000.

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Facilities Planning using Digital Factory

Master Thesis

Table III.4 Routing sheet for Axle Part No. Part Name Drawing No. STG11 Axle DWG11 Operation No. 5

Operation Description Cutting

Machine Big 800 Saw

Machine No. B800

Cycle Fraction Pieces/ Time Equipment Hours

Hours/ pieces

Hours/ 1000

0,165

0,00275

2,75

0,256

363,64

Table III.5 Routing sheet for Tube Plugs Part No. Part Name Drawing No. STG5 Tube Plugs DWG5 Operation No. 75

Operation Description Molding

Machine

65

Trimming

Ergonomic Cutters

NISSEI NS60

Machine No. NS60

Cycle Fraction Pieces/ Time Equipment Hours

Hours/ pieces

Hours/ 1000

0,0625

0,097

960

0,00104

1,042

ERGCT

0,073

0,113

832,918

0,00122

1,217

Machine No. NS60

Cycle Fraction Pieces/ Time Equipment Hours

Hours/ pieces

Hours/ 1000

0,125

0,194

480

0,00208

2,083

ERGCT

0,042

0,065

1428,571

0,0007

0,7

Table III.6 Routing sheet for Leg Extensions Part No. Part Name Drawing No. STG6 Leg DWG6 Extensions Operation No. 75

Operation Description Molding

Machine

65

Trimming

Ergonomic Cutters

NISSEI NS60

Table III.7 Routing sheet for Top Support Part No. Part Name Drawing No. STG8 Top DWG8 Support Operation No. 15

Operation Description Shearing

20

Stamping

25

Bending

45

Painting

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Machine

Machine No.

Cycle Fraction Pieces/ Time Equipment Hours

Hours/ pieces

Hours/ 1000

MINSTER 300 Ton MINSTER 300 Ton MINSTER 300 Ton

MNS300

0,033

0,051

1818,182

0,00055

0,55

MNS300

0,033

0,051

1818,182

0,00055

0,55

MNS300

0,033

0,051

1818,182

0,00055

0,55

IR800

IR800

60

93,023

1

1

1000

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Facilities Planning using Digital Factory

Master Thesis

Table III.8 Routing sheet for Bottom Support Part No. Part Name Drawing No. STG9 Bottom DWG9 Support Operation No. 15

Operation Description Shearing

20

Stamping

25

Bending

10 45

Drilling Painting

Machine

Machine No.

Cycle Fraction Pieces/ Time Equipment Hours

Hours/ pieces

Hours/ 1000

MINSTER 300 Ton MINSTER 300 Ton MINSTER 300 Ton

MNS300

0,033

0,051

1818,182

0,00055

0,55

MNS300

0,033

0,051

1818,182

0,00055

0,55

MNS300

0,033

0,051

1818,182

0,00055

0,55

E2 IR800

E2 IR800

0,246 60

0,381 93,023

243,902 1

0,0041 1

4,1 1000

Table III.9 Routing sheet for Wood Slats Part No. Part Name Drawing No. STG7 Wood Slats DWG7 Operation No. 5

Operation Description Cutting

Machine

Machine No.

Cycle Fraction Pieces/ Time Equipment Hours

Hours/ pieces

Hours/ 1000

Big 800 Saw

B800

0,165

0,256

363,636

0,00275

2,75

10 40

Drilling Sanding

E2

E2

Ryobi Drum Sender

RBS

0,123 0,167

0,191 0,259

487,805 359,281

0,00205 0,00278

2,05 2,783

Table III.10 Routing sheet for Tank Holder Part No. Part Name Drawing No. STG10 Tank DWG10 Holder Operation No. 15

Operation Description Shearing

20

Stamping

25

Bending

10

Drilling

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Machine

Machine No.

Cycle Fraction Pieces/ Time Equipment Hours

Hours/ pieces

Hours/ 1000

MINSTER 300 Ton MINSTER 300 Ton MINSTER 300 Ton

MNS300

0,033

0,051

1818,182

0,00055

0,55

MNS300

0,033

0,051

1818,182

0,00055

0,55

MNS300

0,033

0,051

1818,182

0,00055

0,55

E2

E2

0,246

0,381

243,902

0,0041

4,1

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Facilities Planning using Digital Factory

Master Thesis

Table III.11 Routing sheet for Knob Part No. Part Name Drawing No. STG13 Knob DWG13 Operation No. 75

Operation Description Molding

Machine

65

Trimming

Ergonomic Cutters

NISSEI NS60

Machine No. NS60

Cycle Fraction Pieces/ Time Equipment Hours

Hours/ pieces

Hours/ 1000

0,125

0,194

480

0,00208

2,083

ERGCT

0,060

0,093

1000

0,001

1

Table III.12 Routing sheet for Legs Part No. Part Name Drawing No. STG4 Legs DWG4

Operation No. 5

Operation Description Cutting

10 25

Drilling Bending

35

Deburring

30

Welding

45

Painting

Machine

Machine No.

Cycle Fraction Pieces/ Time Equipment Hours

Hours/ pieces

Hours/ 1000

Big 800 Saw E2 MINSTER 300 Ton Handheld Grinder Lincoln Resistance

B800

0,033

0,051

1818,182

0,00055

0,55

E2 MNS300

0,123 0,167

0,191 0,259

487,805 359,281

0,00205 0,00278

2,05 2,783

IR525

0,125

0,194

480

0,00208

2,083

LR560

0,5

0,775

120

0,00833

8,333

IR800

IR800

60

93,023

1

1

1000

Table III.13 Routing sheet for Control Panel Part No. Part Name Drawing No. STG12 Control DWG12 Panel Operation No. 15

Operation Description Shearing

15

Stamping

15

Bending

35

Deburring

45

Painting

Machine

Machine No.

Cycle Fraction Pieces/ Time Equipment Hours

Hours/ pieces

Hours/ 1000

MINSTER 300 Ton MINSTER 300 Ton MINSTER 300 Ton Handheld Grinder

MNS300

0,033

0,051

1818,182

0,00055

0,55

MNS300

0,099

0,153

606,061

0,00165

1,65

MNS300

0,099

0,153

606,061

0,00165

1,65

IR525

0,125

0,194

480

0,00208

2,083

IR800

IR800

60

93,023

1

1

1000

After finish with routing sheet, I calculate the total of machine requirement using fraction of each routing sheet.

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Facilities Planning using Digital Factory

Master Thesis

Table III.14 Fraction Equipment Spreadsheet Parts/ Equipment Name Wood Saw Metal Saw Shearing Stamping Bending Deburr Sanding Painting Trimming Molding Drilling Welding

Legs STG4

Leg Ext. STG6 -

Wood Slats STG7 0,256

Top Support STG8 -

Bottom Support STG9 -

Tank Holder STG10 -

Axle STG11

-

Tube Plugs STG5 -

0,051 0,259 0,194 93,020 0,191 0,775

0,113 0,097 -

0,065 0,194 -

0,259 0,191 -

0,051 0,051 0,051 93,023 -

0,051 0,051 0,051 93,023 0,246 -

0,051 0,051 0,051 0,381 -

Table III.15 Equipment Used Quantity Equipment Name 1 Big 800 Saw 1 Big 800 Saw 1 MINSTER 300 Ton 1 IR800 IR525 Handheld 3 Grinder 10 Ergonomic Cutters 1 Jutec 850 1 NISSEI NS60 2 E2 1 Ryobi Drum Sander 1

BPS2

Rnd

Knob STG13

Totals

Totals

-

Control Panel STG12 -

-

0,256

1

0,256 -

0,051 0,153 0,153 0,194 93,023 -

0,093 0,194 -

0,307 0,204 0,306 0,565 0,388 0,259 372,092 0,271 0,485 1,009 0,775

1 1 1 1 1 1 373 1 1 1 1

Operation Cutting wood Cutting steel Shearing, stamping Painting (booth)

Machine No. B800 B800 MNS300 IR800

Operation No. 5 5 15, 20 45

Deburring

IR525

35

Trimming plastic Bending Injection Molding Drilling Sanding Vacuuming (bagger)

ERGCT JTC850 NS60 E2 RBS

65 25 75 10 40

J69

80

III.4.2. Assembly Chart and Packaging Line In this sub-chapter, I will present my assembly chart and packaging line layout. Assembly chart was made based on Figure III.3 (exploded view of my gas grill). Line balance of packaging department; cycle time made based on time standard from expert opinion by Industrial Engineering at Moryl GmbH.

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Facilities Planning using Digital Factory

Master Thesis

Grill Legs (2) SA1

Spot Weld (×2)

P1

Paint

Side Support (1) Paint

Control Panel (1) Bottom Support (2)

SA3 Paint

Paint

P3

P2

Paint

Paint

Tank Holder (1)

Wood Slats (4)

SA2

SA4

SA5

Casting Ignitor Grates

SA6

Purchase Parts

Gas Valving Burner Feet & Knob Fasteners Instructions

SA7

Bagging

Poly Bag

Cardboard Box Staples

P.O

Cardboard Packing

Figure III.4 Assembly Chart

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3-17

Facilities Planning using Digital Factory

Master Thesis

Figure III.5 Packaging Line Layout

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3-18

Facilities Planning using Digital Factory

Master Thesis

Line Balance Efficiency of Packaging Department (calculation): 1. Place retainer on conveyor/grill on retainer a. Cycle Time = 0,327 min/piece b. Line Time = 0,335 min/piece (based on busiest operation no.9) c. No. of Station = 0,327 min/piece ÷ 0,645 min/unit = 0,507 station d. No. of Station round up= 1 station e. Avg. Cycle Time = 0,327 min/piece ÷ 1 station = 0,327 min/piece f. % Load = 0,327 min/piece ÷ 0,335 min/piece × 100% = 97,6 % g. Hours/1000 = 0,335 min/piece ÷ 60 min × 1 station × 1000 = 5,5833 h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1 2. Put manifold & grate in grill a. Cycle Time = 0,304 min/piece b. Line Time = 0,335 min/piece c. No. of Station = 0,304 min/piece ÷ 0,645 min/unit = 0,471 station d. No. of Station round up = 1 station e. Avg. Cycle Time = 0,304 min/piece ÷ 1 station = 0,304 min/piece f. % Load = 0,304 min/piece ÷ 0,335 min/piece × 100% = 90,7% g. Hours/1000 = 0,335 min/piece ÷ 60 min × 1 station × 1000 = 5,5833 h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1 3. Put accessories a. Cycle Time = 0,293 min/piece b. Line Time = 0,335 min/piece c. No. of Station = 0,293 min/piece ÷ 0,645 min/unit = 0,454 station d. No. of Station round up = 1 station e. Avg. Cycle Time = 0,293 min/piece ÷ 1 station = 0,293 min/piece f. % Load = 0,293 min/piece ÷ 0,335 min/piece × 100% = 87,5% g. Hours/1000 = 0,335 min/piece ÷ 60 min × 1 station × 1000 = 5,5833 h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1 4. Visually inspect, then close lid a. Cycle Time = 0,275 min/piece b. Line Time = 0,335 min/piece c. No. of Station = 0,275 min/piece ÷ 0,645 min/unit = 0,426 station d. No. of Station round up = 1 station e. Avg. Cycle Time = 0,275 min/piece ÷ 1 station = 0,275 min/piece f. % Load = 0,275 min/piece ÷ 0,335 min/piece × 100% = 82,1% g. Hours/1000 = 0,335 min/piece ÷ 60 min × 1 station × 1000 = 5,5833 h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1 5. Lay legs around grill a. Cycle Time = 0,221 min/piece b. Line Time = 0,335 min/piece c. No. of Station = 0,221 min/piece ÷ 0,645 min/unit = 0,343 station d. No. of Station round up = 1 station e. Avg. Cycle Time = 0,221 min/piece ÷ 1 station = 0,221 min/piece f. % Load = 0,221 min/piece ÷ 0,335 min/piece × 100% = 66% g. Hours/1000 = 0,335 min/piece ÷ 60 min × 1 station × 1000 = 5,5833 h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1 6. Insert control panel/bottom support and tank control a. Cycle Time = 0,334 min/piece b. Line Time = 0,335 min/piece c. No. of Station = 0,334 min/piece ÷ 0,645 min/unit = 0,518 station

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Facilities Planning using Digital Factory

Master Thesis

d. No. of Station round up = 1 station e. Avg. Cycle Time = 0,334 min/piece ÷ 1 station = 0,334 min/piece f. % Load = 0,334 min/piece ÷ 0,335 min/piece × 100% = 99,7% g. Hours/1000 = 0,335 min/piece ÷ 60 min × 1 station × 1000 = 5,5833 h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1 7. Insert wheel & axle/gas hose a. Cycle Time = 0,234 min/piece b. Line Time = 0,335 min/piece c. No. of Station = 0,234 min/piece ÷ 0,645 min/unit = 0,363 station d. No. of Station round up = 1 station e. Avg. Cycle Time = 0,234 min/piece ÷ 1 station = 0,234 min/piece f. % Load = 0,234 min/piece ÷ 0,335 min/piece × 100% = 69,9% g. Hours/1000 = 0,335 min/piece ÷ 60 min × 1 station × 1000 = 5,5833 h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1 8. Visually inspect & wrap cardboard retainer a. Cycle Time = 0,43 min/piece b. Line Time = 0,335 min/piece × 2 = 0,67 min/piece c. No. of Station = 0,43 min/piece ÷ 0,645 min/unit = 0,667 station d. No. of Station round up = 2 station e. Avg. Cycle Time = 0,43 min/piece ÷ 2 station = 0,215 min/piece f. % Load = 0,215 min/piece ÷ 0,335 min/piece × 100% = 64,2% g. Hours/1000 = 0,335 min/piece ÷ 60 min × 2 station × 1000 = 11,1667 h. Pieces/hour = 1 ÷ (11,1667/1000) = 89,552 9. Tape box & put on conveyor a. Cycle Time = 0,335 min/piece b. Line Time = 0,335 min/piece c. No. of Station = 0,335 min/piece ÷ 0,645 min/unit = 0,519 station d. No. of Station round up = 1 station e. Avg. Cycle Time = 0,335 min/piece ÷ 1 station = 0,335 min/piece f. % Load = 0,335 min/piece ÷ 0,335 min/piece × 100% = 100% g. Hours/1000 = 0,335 min/piece ÷ 60 min × 1 station × 1000 = 5,5833 h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1 10. Push grill assembly in box, insert literature, seal box, date, & place on pallet a. Cycle Time = 0,608 min/piece b. Line Time = 0,335 min/piece × 2 = 0,67 min/piece c. No. of Station = 0,608 min/piece ÷ 0,645 min/unit = 0,943 station d. No. of Station round up = 2 station e. Avg. Cycle Time = 0,608 min/piece ÷ 2 station = 0,304 min/piece f. % Load = 0,304 min/piece ÷ 0,335 min/piece × 100% = 90,7% g. Hours/1000 = 0,335 min/piece ÷ 60 min × 2 station × 1000 = 11,1667 h. Pieces/hour = 1 ÷ (11,1667/1000) = 89,552 Notes for line balance calculation:  I use plant rate 0,645 min/unit (see calculation for plant rate)  For line time I use 0,335 min/piece (Avg. Cycle Time operation no 9) for each workstation, if 2 station needed then the line time will be 0,335 × 2 = 0,667 min/piece.  Round up for station if more than 0,6 we use round up 2, if bellow 0,6 we use round up 1

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3-20

Facilities Planning using Digital Factory



Oper ation

1 2 3 4 5

6

7 8 9

10

Master Thesis

For percent load, I use operation no 9 as my base because it is the biggest average cycle time (0,335), this is the busiest operation with 100% load.

Table III.16 Line Balance Efficiency of Packaging Department Operation Cycle Line No. of No. of Avg. % Pcs./Hr. Description Time Time Stat. Stat Cycle Load Time Place retainer on 0,507 1 0,327 97,6 179,100 conveyor/grill on 0,327 0,335 retainer Put manifold & 0,304 0,335 0,471 1 0,304 90,7 179,100 grate in grill 0,293 0,335 0,454 1 0,293 87,5 179,100 Put accessories Visually inspect, 0,275 0,335 0,426 1 0,275 82,1 179,100 then close lid Lay legs around 0,221 0,335 0,343 1 0,221 66,0 179,100 grill Insert control panel/bottom 0,334 0,335 0,518 1 0,334 99,7 179,100 support and tank control Insert wheel & 0,234 0,335 0,363 1 0,234 69,9 179,100 axle/gas hose Visually inspect 0,667 2 0,215 64,2 89,552 & wrap cardboard 0,430 0,670 retainer Tape box & put 0,335 0,335 0,519 1 0,335 100 179,100 on conveyor Push grill assembly in box, 0,943 2 0,304 90,7 89,552 insert literature, 0,608 0,670 seal box, date, & place on pallet

Hrs./1000

5,5833

5,5833 5,5833 5,5833 5,5833

5,5833

5,5833

11,1667

5,5833

11,1667

Total Cycle Time = 3,3614 min/piece Line efficiency = Total Cycle Time ÷ (Total Station × Biggest Average Cycle Time) ×100% = 3,3614 min/piece ÷ (12 station × 0,335 min/piece) ×100% = 83,606% Notes:  Two picking lines will be running per shift  Takt time is 0,645 minute per unit, with line efficiency of 83,6%.

Rezza Prayogi

3-21

Facilities Planning using Digital Factory

Master Thesis

III.4.3 Flow Analysis Technique In this sub-chapter I will use Flow Analysis Technique as qualitative and quantitative tools to design and assess the efficiency of material flow and handling throughout the facility. As with the route sheet, each fabricated part requires process chart which, in addition to value-added process, also identifies non-value-added activities such as storage, delays, material handling, and so on. Process Chart is a valuable tool in assessing non-value-added steps such as excessive material handling, delays, and buildup of work in process (WIP), and helps reduce waste and improve efficiency. The following process charts to identify various costs associated with material handling and other inefficiencies. The form-to chart quantifies the efficiency of the layout resulting from various material movements. Process Chart Part Name : Axle

Summary Operation Transport Inspects Delays Stores Steps Distance

1 2

Storage

Delay

Inspect

Transport

Operation

Step #

Plant : Gas Grill Recorded by : Rezza Prayogi Date : 13 October 2007

Description of Method Receive Delay Inspection Inspection

3 4

6 7 8 9

Method Distance Qty. Mvd. Fork 2267,962 kg truck

Visual

Fork truck

11

Rezza Prayogi

Cost/Unit

0,5

$5,7

0,03 33

$0,38

22,86 m

2267,962 kg

$0,95 $0,95

Fork truck B800

Delay until bin full Transport to Fork packout truck Store at packout Fork truck

10

Hrs./ Unit

for

Delay for transportation Transport to storage Storage Transport to fabrication Cut to length

5

Total 2 3 1 3 2 11 129,54 m

30,48 m

76,2 m

2267,962 kg

1.500 pcs

0,00 275

$0,03

0,08 33

$0,95

1.500 pcs

3-22

Facilities Planning using Digital Factory

Master Thesis

Process Chart Part Name : Tank Holder

Summary Operation Transport Inspects Delays Stores Steps Distance

1 2 3 4 5

Storage

Delay

Inspect

Transport

Operation

Step #

Plant : Gas Grill Recorded by : Rezza Prayogi Date : 13 October 2007

Description of Method Receive steel coil Delay for Inspection Inspection

Method Distance Qty. Mvd. Fork 1 truck

Visual

8

Delay Move warehouse Store Move fabrication Shear

9

Stamp

10

Bend

11

Delay until bin full Transport to Fork drill truck Drill E2

6 7

12 13 14

to Fork truck

22,86 m

1

to Fork truck

30,48 m

1

Move to Fork packaging truck Store at packout

15

Total 4 3 1 3 2 13 129,54 m

15,24 m

76,2 m

1.500

1.500 pcs

Hrs./ Unit

Cost/Unit

0,5

$5,7

0,33 33

$3,8

0,08 33

$0,95

0,08 33 0,00 055 0,00 055 0,00 055

$0,95 $0,01 $0,01 $0,01

0,00 41 0,00 278 0,08 33

$0,05 $0,03 $0,95

Notes: For distance I use ft to m conversion:  50 ft = 15,24 m  75 ft = 22,86 m  100 ft = 30,48 m  250 ft = 76,2 m

Rezza Prayogi

3-23

Facilities Planning using Digital Factory

Master Thesis

Process Chart Part Name : Bottom Support

Summary Operation Transport Inspects Delays Stores Steps Distance

1 2 3 4

Storage

Delay

Inspect

Transport

Operation

Step #

Plant : Gas Grill Recorded by : Rezza Prayogi Date : 13 October 2007

Description of Method Receive steel coil Delay for Inspection Inspection

Method Distance Qty. Mvd. Fork 1 truck

Visual

8

Delay for transportation Transport to storage Storage Transport to fabrication Shear

9

Stamp

10

Bend

11

Delay until bin full Transport to Fork drill truck Drill E2

5 6 7

12 13 14

Delay until bin full Transport to paint Paint Transport to packout Store at packout

15 16 17 18

Rezza Prayogi

Fork truck

22,86 m

1

Fork truck

30,48 m

1

Fork truck

15,24 m

22,86 m

1.500

15,24 m

Hrs./ Unit

Cost/Unit

0,5

$5,7

0,03 33

$0,38

0,08 33

$0,95

0,08 33 0,00 055 0,00 055 0,00 055

$0,95 $0,01 $0,01 $0,01

0,00 41 0,00 278

$0,05 $0,03

1.500

IR800 Fork truck

Total 6 5 1 4 2 18 106,68 m

1.500

1 0,08 33

$11,4 $0,95

3-24

Facilities Planning using Digital Factory

Master Thesis

Process Chart Part Name : Top Support

Summary Operation Transport Inspects Delays Stores Steps Distance

1 2 3 4

Storage

Delay

Inspect

Transport

Operation

Step #

Plant : Gas Grill Recorded by : Rezza Prayogi Date : 13 October 2007

Description of Method Receive steel coil Delay for Inspection Inspection

7

Transport storage Storage Transport fabrication Shear

8

Stamp

9

Bend

10

Delay until bin full Transport to weld Weld Delay until bin full Transport to paint Paint Transport to packout Store at packout

5 6

11 12 13 14 15 16 17

Rezza Prayogi

Method Distance Qty. Mvd. Fork 1 truck

Visual

to Fork truck

22,86 m

1

to Fork truck

30,48 m

1

Fork truck LR560

Fork truck

7,62 m

1.500

22,86 m

1.500

IR800 Fork truck

15,24 m

1.500

Total 6 5 1 3 2 17 99,06 m

Hrs./ Unit

Cost/Unit

0,5

$5,7

0,03 33 0,08 33

$0,38 $0,95

0,08 33 0,00 055 0,00 055 0,00 055

$0,95 $0,01 $0,01 $0,01

0,08 33

$0,95

0,08 33 1 0,08 33

$0,95 $11,4

3-25

Facilities Planning using Digital Factory

Master Thesis

Process Chart Part Name : Packaged Grill

Summary Operation Transport Inspects Delays Stores Steps Distance

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Rezza Prayogi

Storage

Delay

Inspect

Transport

Operation

Step #

Plant : Gas Grill Recorded by : Rezza Prayogi Date : 13 October 2007

Description of Method Grasp retainer Prepare retainer Place retainer on conveyor Grasp grill bottom Place grill bottom on retainer Retainer moves to next operator Grasp manifold Place manifold in grill bottom Grasp griddle Place griddle in grill bottom Grasp heat shield Place heat shield in grill bottom Retainer moves to next operator Grasp fastener kit Place fastener kit in grill bottom Grasp wood slats Place wood slats in grill bottom Grasp plastic component kit Place plastic kit in grill bottom Retainer moves to next operator Perform inspection Grasp grill top

Method Hand Hand Hand

Total 46 10 2 0 0 58 18,288 m

Distance

Qty. Mvd. 1 1 1

Hand Hand Conveyor

1,8288 m = 6ft

1

1,8288 m = 6ft

1

1,8288 m = 6ft

1

Hand Hand Hand Hand Hand Hand Conveyor Hand Hand Hand Hand Hand Hand Conveyor Visual Hand

3-26

Facilities Planning using Digital Factory

23

Place grill top on grill bottom Retainer moves to next operator Grasp leg assemblies Place leg assemblies on grill bottom Retainer moves to next operator Grasp bottom support Insert bottom support Grasp control panel Insert control panel Grasp tank holder Insert tank holder Retainer moves to next operator Grasp axle and wheels Insert axle and wheels Grasp gas hose Insert gas hose Retainer moves to next operator Perform inspection Wrap up retainer Tape retainer together Retainer moves to next operator Grasp box Fold box Tape bottom of box Place box on conveyor Retainer moves to next operator Push retainer assembly into box Grasp literature packet Insert literature packet into box Box moves to next operator Close box Tape top of closed box Grasp time stamper Stamp box with date Grasp box Place box on pallet

24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58

Rezza Prayogi

Master Thesis

Hand Conveyor

1,8288 m = 6ft

1

1,8288 m = 6ft

1

1,8288 m = 6ft

1

1,8288 m = 6ft

1

1,8288 m = 6ft

1

1,8288 m = 6ft

1

1,8288 m = 6ft

1

Hand Hand Conveyor Hand Hand Hand Hand Hand Hand Conveyor Hand Hand Hand Hand Conveyor Visual Hand Hand Conveyor Hand Hand Hand Hand Conveyor Hand Hand Hand Conveyor Hand Hand Hand Hand Hand Hand

3-27

Facilities Planning using Digital Factory

Master Thesis

Flow Process Chart – Axle (STG11) Receiving Delay for Inspection Inspection Delay for Transport Transport to Storage

Storage Transport to Fab Cut to Length Delay until Bin Full Transport to Packout

Store at Packout

Rezza Prayogi

3-28

Facilities Planning using Digital Factory

Master Thesis

Flow Process Chart – Bottom Support (STG9) Receiving Delay for Inspection Inspection

Delay for Transport Transport to Storage

Storage Transport to Fab Shear Stamp Bend Delay until Bin Full To Drill Drill Delay until Bin Full To Paint Paint Transport to Packout Store at Packout

Rezza Prayogi

3-29

Facilities Planning using Digital Factory

Master Thesis

Flow Process Chart – Top Support (STG8) Receiving Delay for Inspection Inspection

Delay for Transport Transport to Storage

Storage Transport to Fab Shear Stamp Bend Delay until Bin Full To Weld Weld Delay until Bin Full To Paint Paint Transport to Packout Store at Packout

Rezza Prayogi

3-30

Facilities Planning using Digital Factory

Master Thesis

Flow Process Chart – Control Panel (STG12) Receiving Delay for Inspection Inspection

Delay for Transport Transport to Storage

Storage Transport to Fab Shear Stamp Bend Delay until Bin Full To Debur Debur Delay until Bin Full To Paint Paint Transport to Packout Store at Packout

Rezza Prayogi

3-31

Facilities Planning using Digital Factory

Master Thesis

Flow Process Chart – Knob (STG13) Receiving Delay for Inspection Inspection Delay for Transport Transport to Storage

Storage Transport to Fab Mold Part Trim Part

Delay until bin Full Transport to Packout

Store at Packout

Rezza Prayogi

3-32

Facilities Planning using Digital Factory

Master Thesis

Flow Process Chart – Leg Extensions (STG6) Receiving Delay for Inspection Inspection Delay for Transport Transport to Storage

Storage Transport to Fab Mold Part Trim Part

Delay until bin Full Transport to Packout

Store at Packout

Rezza Prayogi

3-33

Facilities Planning using Digital Factory

Master Thesis

Flow Process Chart – Tube Plugs (STG5) Receiving Delay for Inspection Inspection Delay for Transport Transport to Storage

Storage Transport to Fab Mold Part Trim Part

Delay until bin Full Transport to Packout

Store at Packout

Rezza Prayogi

3-34

Facilities Planning using Digital Factory

Master Thesis

Flow Process Chart – Wood Slats (STG7) Receiving Delay for Inspection Inspection

Delay for Transport Transport to Storage

Storage Transport to Fab Cut Delay until Bin Full Transport to Drill Drill Delay until Bin Full Transport to Sanding Sand Delay until Bin Full Transport to Packout Store at Packout

Rezza Prayogi

3-35

Facilities Planning using Digital Factory

Master Thesis

Flow Process Chart – Tank Holder (STG10) Receiving Delay for Inspection Inspection

Delay for Transport Transport to Storage

Storage Transport to Fab Shear Stamp Bend Delay until Bin Full To Drill Drill Delay until Bin Full Transport to Packout Store at Packout

Rezza Prayogi

3-36

Facilities Planning using Digital Factory

Master Thesis

Flow Process Chart – Legs (STG4) Receiving Delay for Inspection Inspection Delay for Transport Transport to Storage Storage Transport to Fab Cut Delay until Bin Full Transport to Drill Drill Delay until Bin Full Transport to Debur Debur Delay until Bin Full Transport to Welding Weld Delay until Bin Full Transport to Paint Paint Transport to Packout Store at Packout

Rezza Prayogi

3-37

Facilities Planning using Digital Factory

Master Thesis

Table III. 17 Routing for ten parts Part Name Part No. Routing (Operation Sequence) Axle STG11 RM → C → S Bottom Support STG9 RM → ST → B → D → S Control Panel STG12 RM → ST → B → DB → S Knob STG13 RM → M → S Legs STG4 RM → C → D → B → DB → W → S Leg extensions STG6 RM → M → S Wood slats STG7 RM → C → D → DB → S Tank holder STG10 RM → ST → B → D → S Top support STG8 RM → ST → B → W → S Tube plugs STG5 RM → M → S Notes:  RM = Raw Material  D = Drilling  ST = Stamping  M = Injection Molding  DB = Deburring  W = Welding  B = Bending  S = Storage  C = Cutting

Weight 1 4 4 1 5 1 2 2 4 1

1,1,1

32

21

4,4,2,4 14

Bending Drilling

4,2 6 10

4,5

4 16

27

5

4

2

4,2 30

5,2

Cutting

14

Deburring

4 5

5

Welding Injection Molding Storage

1 4,2

18 4,5 18 1,1,1 3

Penalty Point

Storage

Injection Molding

Welding

Deburring

Cutting

Drilling

1,5,2

4,4,2,4 14

Total

Raw material Stamping

Bending

From

Stamping

To

Raw material

From-To-Chart

25

67

14

14

19

49

13

44

8

18

11

23

9

18

3

3

102

236

From-to-chart calculation:  Penalty point (horizontal direction): o From Raw material to Stamping = 1 × (4+4+2+4) = 14 o From Raw material to Cutting = 4 × (1+5+2) = 32 Rezza Prayogi

3-38

Facilities Planning using Digital Factory

 

Master Thesis

o From Raw material to Injection Mold = 7 × (1+1+1) = 21 o From Stamping to Bending = 1 × (4+4+2+4) = 14 o From Bending to Drilling = 1 × (4+2) = 6 o From Bending to Deburring = 3 × (4+5) = 27 o From Bending to Welding = 4 × (4) = 16 o From Drilling to Deburring = 2 × (2) = 4 o From Drilling to Storage = 5 × (4+2) = 30 o From Cutting to Storage = 4 × (1) = 4 o From Deburring to Welding = 1 × (5) = 5 o From Deburring to Storage = 3 × (4+2) = 18 o From Welding to Storage = 2 × (4+5) = 18 o From Injection Mold to Storage = 1 × (1+1+1) = 3 Penalty point (vertical direction): o From Drilling to Bending = 2 × (5) = 10 o From Cutting to Drilling = 2 × (5+2) = 14 Efficiency: o Efficiency = (Total Weighting ÷ Total Penalty Point) × 100% = 102 ÷ 236 × 100% = 43,22%

Rezza Prayogi

3-39

Facilities Planning using Digital Factory

Master Thesis

III.4.4 Activity Relationship Analysis This sub-chapter will discuss the four techniques for establishing optimal material flow in a manufacturing facility: the activity relationship diagram, the worksheet, the dimensionless block diagram, and the flow analysis. This segment employs the four techniques to determine the most efficient layout possible for my gas grill project. The activity relationship diagram and worksheet show the relationships among the various activities and operation performed in the facility. From that information, a dimensionless block diagram is created showing a proposed layout. Additional flow analysis studies are conducted to better understand the limitation of the design by identifying congested and bottleneck areas. These visual aids can lead the improvement in the design. Activity Relationship Diagram 1 2 3 4 5 6 7 8 9 10 11 12

Fabrication

1 2

Shipping Receiving Warehouse/ Stores Packaging Maintenance Quality Control Offices Cafeteria Tool Room Locker Room

3

A

Painting

4

O O U

5

I

U

O E

A A

E

I

U U U O E U I I U 8

O O U E U

O U O

U

10 O

X C U C U

O

U U

O

X

O

O E

9

I

U

U

8

I O

U

I

7 E 8

O U

U A

6

I

O

11 I

X

I

O O

1

U 2

U U

U

12

3 4

O 5

O 6 7

9

E 10

O 11 12

Notes: A = Absolutely necessary that these tow departments be next to each other E = Especially important I = Important O = Ordinary importance U = Unimportant X = Closeness undesirable

Rezza Prayogi

3-40

Facilities Planning using Digital Factory

Master Thesis

Table III.18 Activity Relationship Worksheet Department A E I 2 7 4,5,8,11,12 1 Fabrication 6 8 2 Painting 5 6 3 Shipping 5 1 4 Receiving 3,4,6 1 5 Warehouse 5 2,3,8 7 6 Packaging 1,11 6,8,12 7 Maintenance 6 1,2,7,12 8 Quality Control 10 9 Offices 9,12 10 Cafeteria 7 1 11 Tool Room 10 1,7,8 12 Locker Room

O U 3,10 6 3,4,5,7,11 12 1,2,8,9,11 4,7,10,12 2,9 3,6,7,8,10,11,12 2,8,12 7,9,10,11 11,12 1,9,10 2,9,10 3,4,5 3,5,9,11 4,10 3,4,7,8,12 5,6,11 1,7 3,4,5,6,8,11 2,3,6,8,12 4,5,9,10 5,6,9,11 2,3,4

X 9 9,10 -

Notes: A = Absolutely necessary that these tow departments be next to each other E = Especially important I = Important O = Ordinary importance U = Unimportant X = Closeness undesirable -

1,11

-

7

7 Maintenance 6,8,12 2

11 Tool Room 2,9,10 7

1 Fabrication 9 4,5,8,11,12 5

1 1

3,10 -

8 3,4,6

1,2,7,12 5

9,10 3,4,5,7,1 -

1 -

9 Offices

7 5

-

11,12 6 3 Shipping

2,8,12 9,12

-

10 Cafeteria

3,4,7,8,12

3,5,9,11 3,4,8 6 Packaging

5 Warehouse/Stores 2,9 10

-

6 8 Quality Control

2,3,6,8,12 6 2 Painting

4 Receiving -

-

1,2,8,9,11 10 12 Locker Room

1,7

1,7,8

5,6,9,11

Figure III.6 Dimensionless Block Diagram

Rezza Prayogi

3-41

Facilities Planning using Digital Factory

Master Thesis

Figure III.7 Flow Diagram for Axle

Rezza Prayogi

3-42

Facilities Planning using Digital Factory

Master Thesis

Figure III.8 Flow Diagram for Tank Holder

Rezza Prayogi

3-43

Facilities Planning using Digital Factory

Master Thesis

Figure III.9 Flow Diagram for Bottom Support

Rezza Prayogi

3-44

Facilities Planning using Digital Factory

Master Thesis

Figure III.10 Flow Diagram for Top Support

Rezza Prayogi

3-45

Facilities Planning using Digital Factory

Master Thesis

Figure III.11 Flow Diagram for Control Panel

Rezza Prayogi

3-46

Facilities Planning using Digital Factory

Master Thesis

Figure III.12 Flow Diagram for Knob, Leg Extensions and Tube Plug

Rezza Prayogi

3-47

Facilities Planning using Digital Factory

Master Thesis

Figure III.13 Flow Diagram for Wood Slats

Rezza Prayogi

3-48

Facilities Planning using Digital Factory

Master Thesis

Figure III.14 Flow Diagram for Legs

Rezza Prayogi

3-49

Facilities Planning using Digital Factory

Master Thesis

III.5. Equipment and Space Used Four preceding sub-chapters dealt with various aspects of space needs assessment and calculations. From space for personal to equipment space requirements, all area allocations for Gas Grill Factory are summarized and presented here. The following figures include layout data for machinery and equipment and equipment space, total spaces and office space requirements for the Gas Grill Factory plant. Keep in mind that overall size of the facility is the sum of all individual units. Every workstation, department, office area, and activity should be considered and its space needs must be analyzed and determined. Therefore, a completed project will have a layout for every work center, office space, and all raw, WIP, and finished inventory. If you do not consider the space needs for a particular inventory item (rework and scrap, too), or where to park material handling equipment, or where to store your pallets, you can rest assured that these items will overflow into the aisles or other undesirable places. This will not only point to lack of foresight on the part of the facilities planner but it will also create an unsafe and congested work environment.

Name/Type: Manufacturer: Electrical : Machine number: Gross Area Needed

Jutec850/Bender Jutec 220V JTC850 106 ft² = 9,8477 m²

Figure III.15 Bender Equipment Layout

Rezza Prayogi

3-50

Facilities Planning using Digital Factory

Name/Type : Manufacturer : Electrical : Machine number : Gross Area Needed :

Master Thesis

Lincoln560/ Resistance Point Welding Lincoln 220V LR560 67 ft² = 6,2245 m²

Figure III.16 Welding Equipment Layout

Name/Type : Manufacturer : Electrical : Machine number : Gross Area Needed :

Radial Saw B800 (Delta) 220V B800 76 ft² = 7,06 m² Figure III.17 Saw Equipment Layout

Rezza Prayogi

3-51

Facilities Planning using Digital Factory

Name/Type : Manufacturer : Electrical : Machine number : Gross Area Needed :

Master Thesis

Drill Press Tradesman 220V 8062 Tradesman 34 ft² = 3,16 m²

Figure III.18 Drill Equipment Layout

Name/Type : Manufacturer : Electrical : Machine number : Gross Area Needed

Stamp Minter 300 220V MNS300 476 ft² = 44,22 m² Figure III.19 Stamp Equipment

Rezza Prayogi

3-52

Facilities Planning using Digital Factory

Name/Type : Manufacturer : Electrical : Machine number : Gross Area Needed :

Master Thesis

Sander RYOBI 220V RBS 31 ft² = 2,879 m²

Figure III.20 Sand Equipment Layout

Name/Type : Manufacturer : Electrical : Machine number : Gross Area Needed :

Poly Bag SHARP 220V J69 64 ft² = 5,945 m² Figure III.21 Poly Equipment

Rezza Prayogi

3-53

Facilities Planning using Digital Factory

Name/Type : Manufacturer : Electrical : Machine number : Gross Area Needed :

Master Thesis

Paint Booth Ingersoll Rand 220V IR800 440 ft² = 40,877 m²

Figure III.22 Paint Equipment Layout

Rezza Prayogi

3-54

Facilities Planning using Digital Factory

Name/Type : Manufacturer : Electrical : Machine number : Gross Area Needed :

Master Thesis

Injection Mold NISSEI 220V NS60 73 ft² = 7,15 m²

Figure III.23 Injection Mold Equipment Layout

Rezza Prayogi

3-55

Facilities Planning using Digital Factory

Part

Master Thesis

Table III.19 Storage Space Calculation Maximum Maximum Size(in) in³ Quantity

Bottom Grill Casting Top Grill Casting Wood Handle Wheels Hub Caps Ignitor Valve Assembly Burner Element Cooking Grid Rock Grate Heat Shield Accessories Bag

Space (in³)

Average Inventory

ft³

Shelf 1×1×3

Pallets 4×4×4

14

16

24

5.376

1.000

5.376.000

2.880.000

1.557,36

0

23,33

16

18

10

2.880

1.000

2.880.000

1.440.000

834,30

0

13,04

10

2

2

40

1.000

40.000

20.000

11,59

3,86

0

6 2 3

6 2 2

2 2 2

72 8 12

2.000 2.000 1.000

144.000 16.000 12.000

72.000 8.000 6.000

41,71 4,63 3,48

13,9 1,54 1,16

0 0 0

10

4

4

160

1.000

160.000

80.000

46,35

15,45

0

12

4

4

192

2.000

384.000

192.000

111,24

37,08

0

14

16 0,5

112

1.000

112.000

56.000

32,44

10,81

0

14 10

16 6

2 6

448 360

1.000 1.000

448.000 360.000

224.000 180.000

129,78 104,29

0 0

2,03 1,63

10

12

12

1.440

1.000

1.440.000

720.000

417,15

139,05

0

3.294,32

222,87

41,03

TOTALS This is PARTIAL listing of parts Shelving units contain 7 shelves Total number of shelving units needed: Total aisle feet for shelving unit:

100 300

Racks can hold 6 pallets (2 high x 3 wide x 1 deep) and measure 15 ft across Total number of racks needed: 50 Total aisle feet for racks: 750 Table III.20 Equipment Space Requirement Machine Name Operation Machine code JUTEC 850 Bender JTC850 DrillPress Drill 8062 TRADESMAN Lincoln Resitance Welder LR560 MINTER 300 Stamp MNS300 Big 800 Wood/Steel Saw B800 RYOBI Sander RBS SHARP Poly Bag J69 Ingersoll Rand Paint Booth IR800 NISSEI Injection Mold NS60

Space Required 106 ft2 = 9,85 m2 34 ft2 = 3,16 m2 67 ft2 = 6,23 m2 476 ft2 = 44,22 m2 152 ft2 = 14,12 m2 31 ft2 = 2,88 m2 64 ft2 = 5,95 m2 440 ft2 = 40,88 m2 73 ft2 = 6,78 m 2

Parking Space Requirement Total employees of first shift is 49 (make round-up to 50) 50 × 1,5 = 75 parking spaces

Rezza Prayogi

3-56

Facilities Planning using Digital Factory

Table III.21 Total Space Requirement Name of the Area Receiving Department Raw Material Storage Fabrication Department Paint Department Packaging Department Finished Goods Storage Shipping Department Offices Maintenance Tool Room Quality Control Locker Room Cafetaria Total Needed

Master Thesis

Space in ft2 Space in m2 750 69,68 4,050 0,38 6,825 0,63 2,260 0,21 7,5 0,70 7,850 0,73 750 69,68 4,150 0,39 400 37,16 170 15,79 170 15,79 1,440 0,13 600 55,74 36,915 3.429,52

Table III.22 Office Space Requirements (Equipment Space) Position Desk/Chair Table File Side Bookcase # Positions Cabinet Chair President 50 ft2 20 ft2 5 ft2 2×8 ft2 3 ft2 1 2 2 2 2 2 VP 50 ft 20 ft 5 ft 2×8 ft 3 ft 1 2 2 2 2 2 Engineer 40 ft 15 ft 5 ft 8 ft 3 ft 2 HR 40 ft2 5 ft2 8 ft2 3 ft2 2 2 2 Secretary 35 ft 5 ft 2 Receptionist 35 ft2 5 ft2 1

Total

Total Space ×2 188 ft2 188 ft2 142 ft2 112 ft2 160 ft2 80 ft2

94 94 71 56 80 40

Table III.23 Total Office Size Position Office Size President 400 ft2 VP 350 ft2 Engineer 300 ft2 HR 250 ft2 Secretary 100 ft2 Receptionist 100 ft2

III.6. Material Handling Equipment Used Material handling equipment requirements for my gas grill factory are summarized in the following figures. Table III.24 Material Handling Equipment Type Description Pneumatic Tire Rider Yale GP-DA/EA Cushion Tire Rider Yale GC-RG Low Lift Walkie Pallet Yale MPB Roller Bed conveyor Hytrol RB

Rezza Prayogi

Quantity 1 3 2 12 (with different length)

3-57

Facilities Planning using Digital Factory

Master Thesis

GENERAL Type

Pneumatic Tire Rider

Yale model design

GP-DA/EA

Capacity range (lb)

16.500 – 36.000

Power Steering

Standard

Yale Hi-Vis mast

Standard ENGINE GM 6.0L V8

Gas Cylinders

8

Figure 11.24 Yale GP-DA/EA Pneumatic I.C.E Lift Truck

Rezza Prayogi

3-58

Facilities Planning using Digital Factory

Master Thesis

GENERAL Type

Cushion Tire Rider

Yale model design

GC-RG

Capacity range (lb)

4000 – 5000

Power Steering

Standard

Yale Hi-Vis mast

Standard ENGINE

Propane

Yale FE

Cylinders

4

Figure III.25 Yale GC-RG Cushion I.C.E Lift Truck

Rezza Prayogi

3-59

Facilities Planning using Digital Factory

Type

Master Thesis

GENERAL Low Lift Walkie Pallet

Yale model design

MPB

Capacity range (lb)

4000 MOTOR

Electric

24 Volt

Figure III.26 Yale MBP Motorized Hand Pallet Truck

Rezza Prayogi

3-60

Facilities Planning using Digital Factory

Master Thesis

GENERAL Type

Live Roller Conveyor

Capacity Range (lb)

15 per roller MOTOR

Drive

Center Drive/Reversible

HP

¾ to 2 HP Available Conveyor Speed

R-Value

0.645 min

Speed (ft/min)

15.5 ft/min

Figure III.27 Hytrol RB Horizontal Bed Conveyor (Roller Bed)

III.7. Cost Calculation This segment of “Gas Grill Project Calculation” will bring the design of a manufacturing facility for the production of the Gas Grill to its conclusion. The following figures show the final layout of the facility. The components of this layout, various departments and activity centers, their locations and their interrelationships, as well their size, are based on the project requirements determined and articulated throughout different stages of the process. Additional data, such as direct and indirect labor costs, some overhead costs, and equipment costs are also presented in this concluding sub-chapter. Although somewhat a cursory approach, an earnest effort has been made to determine the cost and the suggested price of the final product.

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Figure III.28 Final facility layout in 2D

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Table III.25 Salaried Personal Requirement Position No. of Salary* ($) Total Daily Cost** ($) Position President 1 90.000 90.000 450 VP 1 78.000 78.000 390 Engineer 2 54.000 108.000 540 Supervisors 6 48.000 288.000 1.440 HR 1 38.400 38.400 192 *Includes 20% for benefits **Figured on 200 production days per year Table III.26 Hourly Personal Requirement Position Material Handler Machine Operator Packaging Tool and die Maintenance Mechanic Quality Janitor Warehouse Shipping Receiving Secretarial

Shift 1 2nd 3 3 9 9 13 13 1 1 2 2 1 1 1 2 2 2 2 2 2 3 3 3 1 st

3rd 3 9 13 2 1 2 2 2 3 1

$ per hour* Daily Cost 11,4 820,8 11,4 2.462,2 10,20 3.182,4 18 288 13,2 633,6 13,2 105,6 11,4 273,6 11,4 574,2 11,4 574,2 11,4 574,2 11,4 820,8 11,4 456,6

Total Daily Cost

$10.765,60

*Includes 20% for benefits Table III.27 Employee Requirements Shift Hourly Salary Total 1 42 7 49 2 39 2 41 3 38 2 40 Total number of this grill factory employees = 49+41+40 = 130

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Table III.28 Equipment Cost Qu Equipment Name Operation anti ty 1 Big 800 Saw Cutting wood 1 Big 800 Saw Cutting steel 1 MINSTER 300 Ton Shearing, stamping 1 IR 800 Painting 3 IR 525 Handheld Deburring Grinder 10 Ergonomic Cutters Trimming plastic 1 Jutec 850 Bending 1 NISSEI NS60 Injection Molding 2 E2 Drilling 1 Ryobi Drum Sander Sanding 1 BPS2 Vacuum Bagging

Machine No.

Cost per Unit ($)

Total ($)

B800 B800 MNS300 IR800 IR525

400 400 1.100.000 20.000 50

400 400 1.100.000 20.000 150

7,5 1.200 30.000 275 350 4.000

75 1.200 30.000 550 350 4.000

ERGCT JTC850 NS60 E2 RBS J69

Table III.29 Total Cost for a Grill Manufacturer’s Cost Hourly labor cost Salaried cost Raw material cost Purchase parts cost Equipment & facilities cost*

Daily Cost ($) 10.765,60 3.120 4.470 5.000

Per Unit Cost ($) 7,17 2,08 2,98 36,23 3,33 $51,79

*Based on a 10-year payback of $10, with 200 workdays per year, and 300.000 grills per year. The grill will be sold to retailers and distributors for $75 each. The average retail price for this grill will be approximately $119,95. Our profit is $23,21/grill, for a total of $6.963.000/year. As was stated in the introduction to this project, this case study is intended to merely illustrate a systematic approach to designing a manufacturing facility. Successful planning also requires creativity and sound judgment.

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CHAPTER IV BUILDING DIGITAL FACTORY IV.1. Delmia Quest DELMIA QUEST is a complete 3D digital factory environment for process flow simulation and analysis, accuracy, and profitability. QUEST’s flexible, objectbased, discrete event simulation environment combined with powerful visualization and robust import/export capabilities makes it the engineering and management solution of choice for process flow simulation and analysis. DELMIA QUEST provides a single collaborative environment for industrial engineers, manufacturing engineers, and management to develop and prove out best manufacturing flow practices throughout the production design process. Improve designs, reduce risk and cost, and maximize efficiency digitally, before spending money on the actual facility, to get it right the first time. By using QUEST to experiment with parameters such as facility layout, resource allocation, kaizen practices, and alternate scheduling scenarios, integrated product teams can quantify the impact of their decisions on production throughput and cost.

IV.2. Experiment In this sub-chapter, I will present my step by step learning process by doing experiment simulation using Delmia Quest. This experiment is conduct to become more expert in this new system. I give a data and picture that I have created a long with my experiment. IV.2.1 Single machine This experiment will show the basic modelling constructs used to develop a QUEST simulation model. The concepts of a part class and element class are used to build a simple straight-through processing system. Table IV.1 Data for single machine: Source Quantity: 1 Entity Arrival: Exponential (Mean 25 second) Output type: push Entity Quantity: 1 Machine Quantity: 1 Cycle Time: Normal (Mean 25 sec, Standard Deviation 5 sec) Buffer Quantity: 2 Capacity: INF Input/Output type: Push Sink Quantity: 1 Input Type: push Simulation Run: 1000 second Warm Up: 0 sec

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Figure IV.1 Layout for simulation with single machine

Figure IV.2 Simulation with single machine IV.2.2. Three assembly machine This experiment will show the intermediate modelling constructs used to develop a QUEST simulation model. The concepts of a part source, sink, buffer, and machine are expanded and further described. Additional modelling features such as simple route logic, multiple processes, and part requirements are demonstrated. The experiment involves building a straight-through processing system using combinations of multiple sources, buffers, machines, and parts. User-defined names and alternative model scenarios will be established to illustrate model experimentation runs. The system to be modeled in this experiment involves the assembly of three different types of end products on three available flexible machines. Parts PartA, PartB, and PartC are assembled with PartD to form end products PartAD, PartBD, and PartCD, respectively. Machines Mach1, Mach2, and Mach3 require the appropriate part requirements from dedicated upstream buffers to produce the end products on a

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cyclic basis. Assembled products are sent from the machines to a common buffer, after which they exit the system. Table IV.2 Data for three assembly machine: Entity Part Quantity: 4 Part (A,B,C,D) Assembly Quantity: 3 Assy (AD, BD, CD) SourceABC Quantity: 1 Part Fraction: 3 Output type: push Route Logic: Fixed Routing (part restrictions) Interarrival Time: Exponential (mean 15 sec) SourceD Quantity: 1 Part Fraction: 1 Interarrival Time: Constant (15 sec) Machine Input: 4 Part (A,B,C,D) Output: 3 Assy (AD, BD, CD) Cycle Time: Exponential (mean 40 sec) Buffer Quantity: 3 Capacity: INF Input/Output Type: Push Sink Quantity: 1 Capacity: INF Input type: push Simulation Run Time: 1000 sec Warm Up: 0 sec

Figure IV.3 Layout for simulation with three assembly machine

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Figure IV.4 Simulation with three assembly machine IV.2.3. Conveyor system This experiment will show the basic modelling constructs used in developing a basic conveyor system in a QUEST simulation model. The concepts of part, source, sink, buffer, and machine are used in association with different conveyor modelling constructs. The experiment involves building a conveyor system that services two parallel workstations. Table IV.3 Data for conveyor system: Entity Quantity: 2 Source Quantity: 1 Interarrival Time: Normal (Mean 20 sec, standard deviation 4 sec) Part Fraction: 2 Roller Quantity: 1 Conveyor Input/ Output Type: push Capacity: Infinite (INF) Conveyor Type: Accumulating Speed: 0,5 ft/sec Belt Quantity: 8 (connected each) Conveyor Arc Radius: 3 ft Input/ Output Type: push Capacity: Infinite Conveyor Type: non-accumulating Speed: 0,5 ft/sec Decision Point at 1st connection: Process Logic  Unload Part1, Pass Part 2 Machine Quantity: 2 Cycle Time: Uniform (minimum 5 sec, maximum 15 sec) Input/ Output Type: push Buffer Quantity: 3 Capacity: infinite Input/ Output Type: push Sink Quantity: 2 Input Type: push Rezza Prayogi

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Simulation Run: 1000 sec Animation On Step Size: 8 sec Size: 480 sec

Master Thesis

Animation Off Step

Figure IV.5 Layout for simulation with conveyor system

Figure IV.6 Simulation with conveyor system

IV.2.4. Power and Free System This experiment will show the basic modelling constructs used in developing a Power and Free system. The concepts of Power and Free systems, Segments, Decision Points and Carriers are showed here.

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Table IV.4 Data for power and free system: Entity Quantity: 2 Source Quantity: 1 Part Fraction: 2 Interarrival Time: Exponential (mean 45 sec) Sink Quantity: 1 Input Type: Push Buffer Quantity: 1 Input/ Output Type: Push Capacity: Infinite Power and Quantity: 2 Loop (connected) Free Speed: 0,3 ft/sec Segment Dog Spacing: 5 ft Elevation: 10 ft Arc Radius: 3 ft Decision Point at Source: Logic  load Decision Point at Sink: Logic  Unload (claim capacity: 5 at this point) Decision Point at connection: Logic  Route by Part Carrier Quantity: 15 Type: MHS Stopping space: 5 ft Locate Direction: Forward Simulation Runtime: 7200 sec

Figure IV.7 Element in Power and Free System simulation

Figure IV.8 Layout Power and Free with its Decision Point

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Figure IV.8 Simulation with power and free system IV.2.5. Labor, Shift, and Downtime This experiment will show the concepts of labor allocation, shift scheduling, and downtime modelling in a QUEST simulation model. The concepts part, source, sink, buffer, and machine are used in association with labor requirements and their respective shift schedules. The experiment also involves defining equipment downtime and applying them on selected model elements. Table IV.5 Data for labor, shift, and downtime: Entity Quantity: 2 Machine Quantity: 4 Cycle Time: Exponential (mean 20 sec) Buffer Short Quantity: 4 Capacity: 100.000 Buffer Long Quantity: 2 Capacity: 6 Source Quantity: 2 Part Fraction: 1 each part IAT : Exponential (mean 75 sec) Machine Quantity: 4 Input/Output Type: push Cycle Time : Exponential (mean 20 sec) Downtime: Exponential (mean 3600 sec) Time to Repair : Uniform (min 180, max 300) Sink Quantity: 2 Input Type: push Labor controller Quantity: 1 Labor Quantity: 2 Speed: 2 ft/sec Rotation Speed: 360 deg/sec

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Simulation

Move Time: constant 10 sec Break2: 30 min No. of Break: 3 Daily Schedule: start 00:00 – end 09:00 Runtime: 32400 sec (9 hours)

Master Thesis

Break1: 15 minutes

Figure IV.9 Model layout for simulation with Labor

Figure IV.10 Simulation with labor, shift and downtime

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IV.2.6. Labor I This experiment introduces the concept of labor allocation in a QUEST simulation model. In this experiment, the concepts of part, source, sink, buffer, and machine are used in association with labor requirements. Table IV.6. Data for Labor I Simulation Entity Quantity: 2 Machine Quantity: 4 Cycle Time: Exponential (mean 20 sec) Buffer Short Quantity: 4 Capacity: 100.000 Buffer Long Quantity: 2 Capacity: 6 Source Quantity: 2 Part Fraction: 1 each part IAT : Exponential (mean 75 sec) Machine Quantity: 4 Input/Output Type: push Cycle Time : Exponential (mean 20 sec) Sink Labor controller Labor Simulation

Quantity: 2 Input Type: push Quantity: 1 Quantity: 2 Speed: 1 ft/sec Rotation Speed: 360 deg/sec Runtime: 32400 sec (9 hours)

Figure IV.11 Model Layout for simulation with Labor

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Figure IV.12 Completed Model IV.2.7. Labor II This experiment explains another way of modelling the labor in a QUEST model. It explains the concept of labor movement along "via paths". Labor via paths are simple straight line paths created between Labor Points of different elements. In the default method, when the labor is requested to move to an element, a default straight line via path is created between its current Labor_Pt and the destination elements selected Labor_Pt. In the user-created method, the user can create labor via paths between different elements. When it is first created, it is a default straight line path with a starting and ending via points. Additional via points can be added to the via path and their positions/orientation can be modified. Table IV.7. Data for Labor via paths simulation Entity Quantity: 1 Source Quantity: 1 Interarrival Time: Constant 15 sec Machines Quantity: 4 Type: Lathe Cycle Time: constant 15 sec Buffer Quantity: 1 Sink Quantity: 1 Labor controller Quantity: 1 Labor Quantity: 2 Locate labor: on a labor point Speed: 1 ft/sec Rotation Speed: 360 deg/sec Routing Part Part > Routing Requirement > Any Labor Routing Machine Machine > Part Routing (type specific) > Labor Requirement > All Part = Any Machine > Labor Depart Requirement > Any Part

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Routing Source Routing Buffer Simulation

Master Thesis

Combination 1 Source > Part Routing (type specific) > Labor Requirement > All Part = none Buffer > Logics > Route Logic > Cyclic Order Runtime: 1000 sec

Figure IV.13 Layout for Labor experiment via paths

Figure IV.14 Simulation Labor via paths IV.2.8. Labor III This experiment explains another way of modelling the labor in the QUEST model. It explains the concept of labor movement on the path system, a little bit different from previous experiment. Labor movement on a path system is similar to AGV movement. A labor path system element can be created with the segments and

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labor decision points. The labor moves between the labor decision points through the segment connections. Labor has no acceleration or deceleration. Table IV.8. Data for labor movement on path system Entity Quantity: 1 Source Quantity: 1 Interarrival Time: constant 60 sec Sink Quantity: 1 Buffer Quantity: 1 Route Logic: Cyclic order Machine Quantity: 4 Cycle Time: constant 15 sec Labor Segment Quantity: 1 Direction: Bi Directional Max Speed: 0.3ft/sec Labor Controller Quantity: 2 (for left path and right path) Labor Decision Point Quantity: 8 Labor Quantity: 2 Locate labor: on a path system Animation mode: move between point Speed: 1 ft/sec Depart Requirements For labor decision point 1, 2, 3, 5, 6, 7: Any Part =1, Combination-1 For labor decision point 4, 8: Any Part = all 0, no combination Part Destination For every decision point, add fixed part destination for part1 From decision point 1 to decision point 2 From decision point 2 to decision point 3 From decision point 3 to decision point 4 From decision point 5 to decision point 6 From decision point 6 to decision point 7 From decision point 7 to decision point 8 Simulation Runtime: 7200

Figure IV.15 Layout for simulation labor with path system

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Figure IV.16 Simulation labors with its special path system IV.2.9. Pallet This experiment will show how to model pallets (container parts) i.e, parts that can carry other parts. The model that we will construct in this tutorial will have a machine Machine1 that takes in two parts Part1, Part2 and a pallet Pallet1. The machine will pack Part1 and Part2 into Pallet1 and send it on a conveyor. At the end of the conveyor, another machine Machine2 will unpack Pallet1. The parts will be sent to a sink and the pallet will go back to Machine1 to be packed with Part1 and Part2. A pallet is basically a part in QUEST. To add additional display properties like stack points to the pallet, a sub-resource class has to be associated to the pallet's part class. The display attributes of the sub-resource class will then be used by the parts created as pallets. Table IV.9. Data for labor movement on path system Entity Quantity: 2 Sink Quantity:1 Sub-Resource Class Display> No. Stack Point: 2 > 3D display as Plate Stacking table> Part1 > Stack Pt-1 Stacking table> Part2 > Stack Pt-2 Pallet Part Class Quantity:1 Associated Sub-resource class: sub-Resource1 Source Quantity:1 Part Fraction: part 1=1, part2=1, pallet=0 Buffer1 Quantity:1 Unload Process> Part Pre-requisites: change quantity for Any Part=0, Pallet=0, Part1=1, Part2=1 Buffer2 Quantity:2 Part Initial Stock: Pallet=5, Part1=0, Part2=0 Cycle Process Name: Packing Process Part> Quantity> Any Part=0, Part1=1, Part2=1, Pallet=1 Product> Method> Part1 = Pack, Part2 = Pack, Pallet= Pass Through Cycle Process Name: Unpacking Process Part> Quantity> Any Part, Part1, Part2 = 0, Pallet=1 Product> Method> Part1, Part2 = none, Pallet= unpack

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Conveyor Packing Machine Unpacking Machine

Simulation

Master Thesis

Type: Chain long Conveyor Info> Moving Space: 0,32ft Quantity:1 Cycle Process: Packing Process Quantity:1 Cycle Process: Unpacking Process Logic> Route Logic: Fixed Routing Part Routing> Restriction: Part1 route Output1, Part 2 route Ouput1, Pallet route Output2 Runtime: 1000sec

Figure IV.17. Layout for Pallet Simulation

Figure IV.18. Simulation with Pallet

IV.3. Gas Grill Manufacturing Simulation All data in this sub-chapter simulation are based on calculation Chapter 3, in this master thesis. IV.3.1. Axle Production This simulation is based on Routing Sheet, Process Chart, Flow Diagram for Axle in Chapter 3 in this master thesis.

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Table IV.10. Data for Axle Part Production Part Quantity: 1 Name: Axle Source Quantity: 1, Part Initial Stock: 5 IAT: Exponential mean 0,5 hr/unit Unload Process> Part Prerequisites> Axle quantity 5 Buffer Quantity: 1 Unload Process> Part Prerequisites> Axle quantity 5 Machine Quantity: 1 Name: SawB800 Type: cutting Cycle Time: Exponential mean 0,00275 hr/unit Rejection Rate: 1% Conveyor Type: Roller Accumulating, Quantity:1 Speed: 15,5 ft/min or 283.464 m/hr Labor Segment Quantity:3 Direction: Bi Directional Max Speed: 10800m/hr Labor Controller Quantity:3 for 2 labor as forklift with capacity number: 5 part Labor Decision Point Quantity: 7 Labor controller depend on its area Labor Quantity: 3, 1 as human, 1 as forklift, and 1 as hand pallet truck Depart Requirements For decision point 1,3,5,6: Any Part = 1, Combination-1 For decision point 2,4,7: Any Part = all 0, no Combination Part Destination For every decision point, add fixed part destination for Axle From decision point 1 to decision point 2 From decision point 2 to decision point 3 From decision point 3 to decision point 4 From decision point 5 to decision point 6 From decision point 6 to decision point 7 Simulation Runtime: 24hr Labor Controller3 Sink Labor Controller2 Dec_Point6,7 Machine Dec_Point3,4,5 Dec_Point1,2 Labor Source Forklift Labor Controller1 Figure IV.19 Layout for Axle production simulation Rezza Prayogi

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Figure IV.20 Step 1 simulation with forklift bring raw material for axle

Figure IV.21 Step 2 simulation with material in cutting machine

Figure IV.22 Step 3 simulation with finished axle going to packout

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IV.3.2. Tank Holder Production This simulation is based on Routing Sheet, Process Chart, Flow Diagram for Tank Holder part in Chapter 3 in this master thesis. Table IV.11. Data for Tank Holder Part Production Part Quantity: 1 Name: Tank Holder Source Quantity: 1, Part Initial Stock: 5 IAT: Exponential mean 0,5 hr/unit Unload Process> Part Prerequisites> Tank Holder quantity 5 Buffer Quantity: 3 Unload Process> Part Prerequisites> Tank Holder quantity 5 Machine1 Quantity: 1 Name: Minter300 Type: Shearing Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: 0,5% Machine2 Quantity:1 Name: Minter300 Type: Stamping Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: 0,25% Machine3 Quantity:1 Name: Jutec850 Type: Bending Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: Machine 4 Quantity:1 Name: Tradesman Type: Drilling Cycle Time: Exponential mean 0,00278 hr/unit Rejection Rate: 0,25% Conveyor Type: Roller Accumulating, Quantity:3 Speed: 15,5 ft/min or 283.464 m/hr Labor Segment Quantity:6 Direction: Bi Directional Max Speed: 10800m/hr Labor Controller Quantity: 6 for 3 labor as forklift with capacity number: 5 part Labor Decision Point Quantity: 16 Labor controller depend on its area Labor Quantity: 6, 4 as human, 1 as forklift, and 1 as hand pallet truck Depart Requirements For decision point 1,3,4,5,7,8,10,12,13,15: Any Part = 1, Combination-1 For decision point 2,6,9,11,14,16: Any Part = all 0, no Combination Part Destination For every decision point, add fixed part destination for Tank Holder From decision point 1 to decision point 2 From decision point 2 to decision point 3 From decision point 3 to decision point 4 From decision point 5 to decision point 6 From decision point 6 to decision point 7 From decision point 7 to decision point 8 From decision point 8 to decision point 9 From decision point 9 to decision point 10 From decision point 10 to decision point 11 From decision point 11 to decision point 12 From decision point 13 to decision point 14 From decision point 14 to decision point 15 From decision point 15 to decision point 16 Simulation Runtime: 24hr

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Drilling Machine

Roller Conveyor Labor Segment Bending Machine

Labor

Stamping Machine

Source Forklift

Shearing Machine

Figure IV.23 Layout for Tank Holder Simulation

Figure IV.24 Step 1 simulation with forklift bring raw material to production

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Figure IV.25 Step 2 simulation with material in shearing and stamping machine

Figure IV.26 Step 3 simulation with material in bending machine

Figure IV.27 Step 4 simulation with material in drilling machine Rezza Prayogi

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Figure IV.28 Step 5 simulation with finished tank holder going to packout IV.3.3. Bottom Support Production This simulation is based on Routing Sheet, Process Chart, Flow Diagram for Bottom Support part in Chapter 3 in this master thesis. Table IV.12. Data for Bottom Support Part Production Part Quantity: 1 Name: Bottom Support Source Quantity: 1, Part Initial Stock: 5 IAT: Exponential mean 0,5 hr/unit Unload Process> Part Prerequisites> Bottom Support quantity 5 Buffer Quantity: 3 Unload Process> Part Prerequisites> Bottom Support quantity 5 Machine1 Quantity: 1 Name: Minter300 Type: Shearing Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: 0,5% Machine2 Quantity:1 Name: Minter300 Type: Stamping Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: 0,25% Machine3 Quantity:1 Name: Jutec850 Type: Bending Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: Machine 4 Quantity:1 Name: Tradesman Type: Drilling Cycle Time: Exponential mean 0,00278 hr/unit Rejection Rate: 0,25% Conveyor Type: Roller Accumulating, Quantity:3 Speed: 15,5 ft/min or 283.464 m/hr Labor Segment Quantity:8 Direction: Bi Directional Max Speed: 10800m/hr Labor Controller Quantity: 8 for 3 labor as forklift with capacity number: 5 part Labor Decision Point Quantity: 20 Labor controller depend on its area Labor Quantity: 6, 4 as human, 1 as forklift, and 1 as hand pallet truck Depart Requirements For decision point 1,3,4,5,7,8,10,12,13,15,17,19: Any Part = 1, Combination-1 For decision point 2,6,9,11,14,16,18,20: Any Part = all 0, no Combination Part Destination For every decision point, add fixed part destination for Bottom

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Support From decision point 1 to decision point 2 From decision point 2 to decision point 3 From decision point 3 to decision point 4 From decision point 5 to decision point 6 From decision point 6 to decision point 7 From decision point 7 to decision point 8 From decision point 8 to decision point 9 From decision point 9 to decision point 10 From decision point 10 to decision point 11 From decision point 11 to decision point 12 From decision point 13 to decision point 14 From decision point 14 to decision point 15 From decision point 15 to decision point 16 From decision point 16 to decision point 17 From decision point 17 to decision point 18 From decision point 18 to decision point 19 From decision point 19 to decision point 20 Power and Free Quantity: 1 Loop (connected) Speed: 0,3 ft/sec Segment (for painting) Dog Spacing: 5 ft Elevation: 10 ft Arc Radius: 3 ft Decision Point at Source: Logic  load Decision Point at Sink: Logic  Unload (claim capacity: 5 at this point) Carrier Quantity: 10 Type: MHS Stopping space: 5 ft Locate Direction: Forward Simulation Runtime: 24hr

Painting

Drilling Bending

Source

Stamping Shearing Figure IV.29 Layout for Bottom Support production simulation Rezza Prayogi

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Figure IV.30 Step 1 with Forklift bring raw material to production area

Figure VI.31 Step 2 with material in shear and stamp machine

Figure IV.32 Step 3 with material in bend machine

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Figure IV.33 Step 4 with material in drill machine

Figure IV.34 Step 5 with finished product ready to enter paint area

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Figure IV.35 Step 6 with finished product ready to enter Packout area IV.3.4. Top Support Production This simulation is based on Routing Sheet, Process Chart, Flow Diagram for Top Support part in Chapter 3 in this master thesis. Table IV.13. Data for Top Support Part Production Part Quantity: 1 Name: Top Support Source Quantity: 1, Part Initial Stock: 5 IAT: Exponential mean 0,5 hr/unit Unload Process> Part Prerequisites> Top Support quantity 5 Buffer Quantity: 3 Unload Process> Part Prerequisites> Top Support quantity 5 Machine1 Quantity: 1 Name: Minter300 Type: Shearing Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: 0,5% Machine2 Quantity:1 Name: Minter300 Type: Stamping Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: 0,25% Machine3 Quantity:1 Name: Jutec850 Type: Bending Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: Machine 4 Quantity:1 Name: Lincoln 560 Type: Welding Cycle Time: Exponential mean 0,00278 hr/unit Rejection Rate: Conveyor Type: Roller Accumulating, Quantity:3 Speed: 15,5 ft/min or 283.464 m/hr Labor Segment Quantity:8 Direction: Bi Directional Max Speed: 10800m/hr Labor Controller Quantity: 8 for 3 labor as forklift with capacity number: 5 part Labor Decision Point Quantity: 20 Labor controller depend on its area Labor Quantity: 6, 4 as human, 1 as forklift, and 1 as hand pallet truck Depart Requirements For decision point 1,3,4,5,7,8,10,12,13,15,17,19: Any Part = 1,

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Combination-1 For decision point 2,6,9,11,14,16,18,20: Any Part = all 0, no Combination Part Destination For every decision point, add fixed part destination for Bottom Support From decision point 1 to decision point 2 From decision point 2 to decision point 3 From decision point 3 to decision point 4 From decision point 5 to decision point 6 From decision point 6 to decision point 7 From decision point 7 to decision point 8 From decision point 8 to decision point 9 From decision point 9 to decision point 10 From decision point 10 to decision point 11 From decision point 11 to decision point 12 From decision point 13 to decision point 14 From decision point 14 to decision point 15 From decision point 15 to decision point 16 From decision point 16 to decision point 17 From decision point 17 to decision point 18 From decision point 18 to decision point 19 From decision point 19 to decision point 20 Power and Free Quantity: 1 Loop (connected) Speed: 0,3 ft/sec Segment (for painting) Dog Spacing: 5 ft Elevation: 10 ft Arc Radius: 3 ft Decision Point at Source: Logic  load Decision Point at Sink: Logic  Unload (claim capacity: 5 at this point) Carrier Quantity: 10 Type: MHS Stopping space: 5 ft Locate Direction: Forward Simulation Runtime: 24hr

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Paint Area

Welding

Bending Source Stamping Shearing Figure IV.36 Layout for Top Support production simulation

Figure IV.37 Step 1 with forklift bring raw material to production area Rezza Prayogi

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Figure IV.38 Step 2 with material in shear and stamp machine

Figure IV.39 Step 3 with material in bend machine

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Figure IV.40 Step 4 with material in weld machine

Figure IV.41 Step 5 with finished product ready to enter paint area

Figure IV.42 Step 6 with finished product ready to enter Packout area

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IV.3.5. Control Panel Production This simulation is based on Routing Sheet, Process Chart, Flow Diagram for Control Panel part in Chapter 3 in this master thesis. Table IV.14. Data for Control Panel Part Production Part Quantity: 1 Name: Control Panel Source Quantity: 1, Part Initial Stock: 5 IAT: Exponential mean 0,5 hr/unit Unload Process> Part Prerequisites> Control Panel quantity 5 Buffer Quantity: 3 Unload Process> Part Prerequisites> Control Panel quantity 5 Machine1 Quantity: 1 Name: Minter300 Type: Shearing Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: 0,5% Machine2 Quantity:1 Name: Minter300 Type: Stamping Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: 0,25% Machine3 Quantity:1 Name: Jutec850 Type: Bending Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: Machine 4 Quantity:1 Name: RYOBI Type: Sander/Grinder Cycle Time: Exponential mean 0,00208 hr/unit Rejection Rate: 0,5% Conveyor Type: Roller Accumulating, Quantity:3 Speed: 15,5 ft/min or 283.464 m/hr Labor Segment Quantity:8 Direction: Bi Directional Max Speed: 10800m/hr Labor Controller Quantity: 8 for 3 labor as forklift with capacity number: 5 part Labor Decision Point Quantity: 20 Labor controller depend on its area Labor Quantity: 6, 4 as human, 1 as forklift, and 1 as hand pallet truck Depart Requirements For decision point 1,3,4,5,7,8,10,12,13,15,17,19: Any Part = 1, Combination-1 For decision point 2,6,9,11,14,16,18,20: Any Part = all 0, no Combination Part Destination For every decision point, add fixed part destination for Control Panel From decision point 1 to decision point 2 From decision point 2 to decision point 3 From decision point 3 to decision point 4 From decision point 5 to decision point 6 From decision point 6 to decision point 7 From decision point 7 to decision point 8 From decision point 8 to decision point 9 From decision point 9 to decision point 10 From decision point 10 to decision point 11 From decision point 11 to decision point 12 From decision point 13 to decision point 14 From decision point 14 to decision point 15 From decision point 15 to decision point 16 From decision point 16 to decision point 17 Rezza Prayogi

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From decision point 17 to decision point 18 From decision point 18 to decision point 19 From decision point 19 to decision point 20 Power and Free Quantity: 1 Loop (connected) Speed: 0,3 ft/sec Segment (for painting) Dog Spacing: 5 ft Elevation: 10 ft Arc Radius: 3 ft Decision Point at Source: Logic  load Decision Point at Sink: Logic  Unload (claim capacity: 5 at this point) Carrier Quantity: 10 Type: MHS Stopping space: 5 ft Locate Direction: Forward Simulation Runtime: 24hr

Painting Area

Deburring

Bending Source Stamping Shearing

Figure IV.43 Layout for Control Panel production simulation

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Figure IV.44 Step 1 with forklift bring raw material to production area

Figure IV.45 Step 2 with material in shear and stamp machine

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Figure IV.46 Step 3 with material in bend machine

Figure IV.47 Step 4 with material in debur / grind machine

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Figure IV.48 Step 5 with finished product ready to enter paint area

Figure IV.49 Step 6 with finished product ready to enter Packout area IV.3.6. Tube Plugs Production This simulation is based on Routing Sheet, Process Chart, Flow Diagram for Tube Plugs in Chapter 3 in this master thesis. Table IV.15. Data for Tube Plugs Part Production Part Quantity: 1 Name: Tube Plugs Source Quantity: 1, Part Initial Stock: 5 IAT: Exponential mean 0,5 hr/unit Unload Process> Part Prerequisites> Tube Plugs quantity 5 Buffer Quantity: 1 Unload Process> Part Prerequisites> Tube Plugs quantity 5 Machine Quantity: 1 Name: NISSEI NS60 Type: Molding

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Conveyor Labor Segment Labor Controller Labor Decision Point Labor Depart Requirements Part Destination

Simulation

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Cycle Time: Exponential mean 0,00104 hr/unit Rejection Rate: 1% Quantity: 1 Name: ERGCT Type: Trim Cycle Time: Exponential mean 0,00122 hr/unit Rejection Rate: 0,1% Quantity:1 Type: Roller Accumulating Speed: 15,5 ft/min or 283.464 m/hr Quantity:3 Direction: Bi Directional Max Speed: 10800m/hr Quantity:3 for 2 labor as forklift with capacity number: 5 part Quantity: 8 Labor controller depend on its area Quantity: 3, 1 as human, 1 as forklift, and 1 as hand pallet truck For decision point 1,3,4,5,7: Any Part = 1, Combination-1 For decision point 2,6,8: Any Part = all 0, no Combination For every decision point, add fixed part destination for Tube Plugs From decision point 1 to decision point 2 From decision point 2 to decision point 3 From decision point 3 to decision point 4 From decision point 5 to decision point 6 From decision point 6 to decision point 7 From decision point 7 to decision point 8 Runtime: 24hr

Sink Hand pallet truck Bin Trim machine Mold machine Forklift Roller Conveyor

Source

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Figure IV.51 Step 1 with forklift bring raw material to production area

Figure IV.52 Step 2 with material in Mold and Trim machine

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Figure IV.53 Step 3 with finished product ready to enter Packout area IV.3.7. Leg Extensions Production This simulation is based on Routing Sheet, Process Chart, and Flow Diagram for Leg Extensions in Chapter 3 in this master thesis. Table IV.16. Data for Leg Extensions Part Production Part Quantity: 1 Name: Leg Extensions Source Quantity: 1, Part Initial Stock: 5 IAT: Exponential mean 0,5 hr/unit Unload Process> Part Prerequisites> Leg Extensions quantity 5 Buffer Quantity: 1 Unload Process> Part Prerequisites> Leg Extensions quantity 5 Machine Quantity: 1 Name: NISSEI NS60 Type: Molding Cycle Time: Exponential mean 0,00204 hr/unit Rejection Rate: 1% Machine Quantity: 1 Name: ERGCT Type: Trim Cycle Time: Exponential mean 0,0007 hr/unit Rejection Rate: 0,1% Conveyor Quantity:1 Type: Roller Accumulating Speed: 15,5 ft/min or 283.464 m/hr Labor Segment Quantity:3 Direction: Bi Directional Max Speed: 10800m/hr Labor Controller Quantity:3 for 2 labor as forklift with capacity number: 5 part Labor Decision Point Quantity: 8 Labor controller depend on its area Labor Quantity: 3, 1 as human, 1 as forklift, and 1 as hand pallet truck Depart Requirements For decision point 1,3,4,5,7: Any Part = 1, Combination-1 For decision point 2,6,8: Any Part = all 0, no Combination Part Destination For every decision point, add fixed part destination for Leg Extensions

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From decision point 1 to decision point 2 From decision point 2 to decision point 3 From decision point 3 to decision point 4 From decision point 5 to decision point 6 From decision point 6 to decision point 7 From decision point 7 to decision point 8 Runtime: 24hr

Simulation

Sink Hand pallet truck Bin Trim machine Mold machine Forklift Roller Conveyor

Source

Figure IV.54 Layout for Leg Extensions Production

Figure IV.55 Step 1 with forklift bring raw material to production area Rezza Prayogi

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Figure IV.56 Step 2 with material in Mold and Trim machine

Figure IV.57 Step 3 with finished product ready to enter Packout area

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IV.3.8. Knob Production This simulation is based on Routing Sheet, Process Chart, and Flow Diagram for Knob in Chapter 3 in this master thesis. Table IV.17. Data for Knob Part Production Part Quantity: 1 Name: Knob Source Quantity: 1, Part Initial Stock: 5 IAT: Exponential mean 0,5 hr/unit Unload Process> Part Prerequisites> Knob quantity 5 Buffer Quantity: 1 Unload Process> Part Prerequisites> Knob quantity 5 Machine Quantity: 1 Name: NISSEI NS60 Type: Molding Cycle Time: Exponential mean 0,00208 hr/unit Rejection Rate: 1% Machine Quantity: 1 Name: ERGCT Type: Trim Cycle Time: Exponential mean 0,001 hr/unit Rejection Rate: 0,1% Conveyor Quantity:1 Type: Roller Accumulating Speed: 15,5 ft/min or 283.464 m/hr Labor Segment Quantity:3 Direction: Bi Directional Max Speed: 10800m/hr Labor Controller Quantity:3 for 2 labor as forklift with capacity number: 5 part Labor Decision Point Quantity: 8 Labor controller depend on its area Labor Quantity: 3, 1 as human, 1 as forklift, and 1 as hand pallet truck Depart Requirements For decision point 1,3,4,5,7: Any Part = 1, Combination-1 For decision point 2,6,8: Any Part = all 0, no Combination Part Destination For every decision point, add fixed part destination for Knob From decision point 1 to decision point 2 From decision point 2 to decision point 3 From decision point 3 to decision point 4 From decision point 5 to decision point 6 From decision point 6 to decision point 7 From decision point 7 to decision point 8 Simulation Runtime: 24hr

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Sink Hand pallet truck Bin Trim machine Mold machine Forklift Roller Conveyor

Source

Figure IV.58 Layout for Knob Production

Figure IV.59 Step 1 with forklift bring raw material to production area

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Figure IV.60 Step 2 with material in Mold and Trim machine

Figure IV.61 Step 3 with finished product ready to enter Packout area

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IV.3.9. Legs Production This simulation is based on Routing Sheet, Process Chart, Flow Diagram for Legs part in Chapter 3 in this master thesis. Table IV.18. Data for Legs Part Production Part Quantity: 1 Name: Legs Source Quantity: 1, Part Initial Stock: 5 IAT: Exponential mean 0,5 hr/unit Unload Process> Part Prerequisites> Legs quantity 5 Buffer Quantity: 3 Unload Process> Part Prerequisites> Legs quantity 5 Machine1 Quantity: 1 Name: Big Saw 800 Type: Cutting Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: 1% Machine2 Quantity:1 Name: E2 Type: Drilling Cycle Time: Exponential mean 0,00205 hr/unit Rejection Rate: 0,25% Machine3 Quantity:1 Name: Jutec850 Type: Bending Cycle Time: Exponential mean 0,00278 hr/unit Rejection Rate: Machine 4 Quantity:1 Name: Grind IR525 Type: Deburring Cycle Time: Exponential mean 0,00208 hr/unit Rejection Rate: 0,5% Machine 5 Quantity:1 Name: Lincoln LR560 Type: Welding Cycle Time: Exponential mean 0,00833 hr/unit Rejection Rate: Conveyor Type: Roller Accumulating, Quantity:3 Speed: 15,5 ft/min or 283.464 m/hr Labor Segment Quantity:8 Direction: Bi Directional Max Speed: 10800m/hr Labor Controller Quantity: 8 for 3 labor as forklift with capacity number: 5 part Labor Decision Point Quantity: 20 Labor controller depend on its area Labor Quantity: 6, 4 as human, 1 as forklift, and 1 as hand pallet truck Depart Requirements For decision point 1,3,4,5,7,8,10,12,13,15,17,19: Any Part = 1, Combination-1 For decision point 2,6,9,11,14,16,18,20: Any Part = all 0, no Combination Part Destination For every decision point, add fixed part destination for Legs From decision point 1 to decision point 2 From decision point 2 to decision point 3 From decision point 3 to decision point 4 From decision point 5 to decision point 6 From decision point 6 to decision point 7 From decision point 7 to decision point 8 From decision point 8 to decision point 9 From decision point 9 to decision point 10 From decision point 10 to decision point 11 From decision point 11 to decision point 12 From decision point 13 to decision point 14

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From decision point 14 to decision point 15 From decision point 15 to decision point 16 From decision point 16 to decision point 17 From decision point 17 to decision point 18 From decision point 18 to decision point 19 From decision point 19 to decision point 20 Power and Free Quantity: 1 Loop (connected) Speed: 0,3 ft/sec Segment (for painting) Dog Spacing: 5 ft Elevation: 10 ft Arc Radius: 3 ft Decision Point at Source: Logic  load Decision Point at Sink: Logic  Unload (claim capacity: 5 at this point) Carrier Quantity: 10 Type: MHS Stopping space: 5 ft Locate Direction: Forward Simulation Runtime: 24hr

Painting area

Welding Deburring

Bending Welding

Source

Cutting

Figure IV.62 Layout for Legs production simulation

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Figure IV.63 Step 1 with

Figure IV.64 Step 2 with material in cut and drill machine

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Figure IV.65 Step 3 with material in bend machine

Figure IV.66 Step 4 with material in debur and weld machine

Figure IV.67 Step 5 with material ready to enter paint area

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Figure IV.68 Step 6 with finished product ready to enter Packout area IV.3.10. Wood Slats Production This simulation is based on Routing Sheet, Process Chart, Flow Diagram for Wood Slats part in Chapter 3 in this master thesis. Table IV.18. Data for Wood Slats Part Production Part Quantity: 1 Name: Wood Slats Source Quantity: 1, Part Initial Stock: 5 IAT: Exponential mean 0,5 hr/unit Unload Process> Part Prerequisites> Wood Slats quantity 5 Buffer Quantity: 3 Unload Process> Part Prerequisites> Wood Slats quantity 5 Machine1 Quantity: 1 Name: Big Saw 800 Type: Cutting Cycle Time: Exponential mean 0,00055 hr/unit Rejection Rate: 1% Machine 2 Quantity:1 Name: Grind IR525 Type: Sanding Cycle Time: Exponential mean 0,00208 hr/unit Rejection Rate: 0,5% Conveyor Type: Roller Accumulating, Quantity:3 Speed: 15,5 ft/min or 283.464 m/hr Labor Segment Quantity:8 Direction: Bi Directional Max Speed: 10800m/hr Labor Controller Quantity: 8 for 3 labor as forklift with capacity number: 5 part Labor Decision Point Quantity: 20 Labor controller depend on its area Labor Quantity: 6, 4 as human, 1 as forklift, and 1 as hand pallet truck Depart Requirements For decision point 1,3,4,5,7,8,10,12,13,15,17,19: Any Part = 1, Combination-1 For decision point 2,6,9,11,14,16,18,20: Any Part = all 0, no Combination Part Destination For every decision point, add fixed part destination for Wood Slats

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From decision point 1 to decision point 2 From decision point 2 to decision point 3 From decision point 3 to decision point 4 From decision point 5 to decision point 6 From decision point 6 to decision point 7 From decision point 7 to decision point 8 From decision point 8 to decision point 9 From decision point 9 to decision point 10 From decision point 10 to decision point 11 From decision point 11 to decision point 12 From decision point 13 to decision point 14 From decision point 14 to decision point 15 From decision point 15 to decision point 16 From decision point 16 to decision point 17 From decision point 17 to decision point 18 From decision point 18 to decision point 19 From decision point 19 to decision point 20 Power and Free Quantity: 1 Loop (connected) Speed: 0,3 ft/sec Segment (for painting) Dog Spacing: 5 ft Elevation: 10 ft Arc Radius: 3 ft Decision Point at Source: Logic  load Decision Point at Sink: Logic  Unload (claim capacity: 5 at this point) Carrier Quantity: 10 Type: MHS Stopping space: 5 ft Locate Direction: Forward Simulation Runtime: 24hr

Cutting Sink Drilling

Sanding

Source

Figure IV.69 Layout for Wood Slats production simulation

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Figure IV.70 Step 1 with raw material being transported to production area

Figure IV.71 Step 2 with material in cutting and drilling machine

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Figure IV.72 Step 3 with material in sanding machine

Figure IV.73 Step 4 with finished product being transported to Packout area

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Chapter V Conclusion V.1. Advantages Here is the list of advantages using Digital Factory for Facilities Planning: 1. Picture is better than words and 3D picture is better than 2D Picture. 2. Simulation is than picture and 3D simulation is better than 2D simulation. 3. People who create Digital Factory, have more understanding about their factory than using only manual calculation. 4. From simulation in digital factory we can see animation (how our factory working), cost/workcell, total cost, is our product really created in correct order, bottleneck, and so on. 5. The simulation software generates reports and detailed statistics describing the behavior of the system under study. Based on these reports, the physical layouts, equipment selection, operating procedures, resource allocation and utilization, inventory policies, and other important system characteristics can be evaluated. 6. Simulation modeling is dynamic, in that the behavior of the model is tracked over time. 7. You can play with your factory without disrupting the real one because virtual take no cost like the real one. 8. Computer simulation allows the comparison of different alternatives and studies various scenarios in order to select the most suitable setup. 9. Simulation can be used to predict the behavior of a manufacturing or service system by actually tracking the movements and interaction of the system components and aiding in optimization such systems. 10. Digital Factory can be utilized to study and optimize the layout and capacity, JIT inventory policies, material handling systems, and warehousing and logistics planning.

V.2. Disadvantages Here is the list of disadvantages using Digital Factory for Facilities Planning: 1. Cost for Software is high. 2. Cost for computer hardware is high (because we need more powerful PC than ordinary one). 3. Need time for learning software that used in digital factory. 4. Needed a lot of assumption for a new factory data. 5. If you give a wrong data, the result will be wrong (Garbage In Garbage Out). 6. Simulation is a stochastic process, meaning random occurrences must be studied before. 7. You must understand statistic first, because simulation use distribution fitting for data enter. 8. You must understand programming language, because sometime the software doesn’t have logics, command, and procedures for our special case.

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LIBRARY

 Books:  Facilities Planning, 2nd ed. Tompkins, White, Bozer, Frazelle, Tanchoco, Trevino. McGraw-Hill 1996.  Production Planning and Inventory Control, 5th ed. Vincent Gasperz. Gramedia 2005.  Simulation using ProModel, 2nd ed. Harrel, Gosh, Bowden. McGrawHill 2000.  Reinhard, G.; Grundwald, S.; Rick, F.: Virtuelle Produktion – Virtuelle Produkte im Rechner produzieren. In: VDI-Z, 141, (1999) 12, S. 26  Internet:  http://www.3ds.com. Delmia Manual Book, Dassault System.  http://www.mcadonline.com. Free Digital Prototyping magazine

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APPENDIX

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APPENDIX I DELMIA QUEST MODELING TERMS This section lists and describes the major QUEST modelling and terms used throughout the QUEST documentation set and software. The terms are arranged in alphabetical order for ease in accessing them. If a term can be used in more than one category, the description will reference those categories, e.g., decision point can be found under AGV decision point, conveyor decision point, etc. Accessory Class An accessory class is a set of accessory elements that relate to the same class level set of data, e.g., display geometry. An accessory class can be saved with a model file or in a separate file so as to allow its use with different models. Accessory Element Accessory is an element with static geometry provided for visualization purposes, and has no effect on the simulation results. AGV Class An AGV class is a Material Handling System (MHS) element class. It is a set of AGV elements that relate to the same class level set of data, e.g., display geometry, acceleration, deceleration, process logic. An AGV class definition can be saved with the model file, or in a separate file so as to allow its use with different models. AGV Command An AGV command is an instruction to an AGV to perform some action given by the AGV controller and AGV decision points. AGV commands are processed in the AGV process logic. Users can create their own commands. AGV Controller An AGV controller is an MHS element. It is used to globally control one or many AGV classes with respect to a set of AGV decision points. Each AGV class and decision point can only belong to one controller. An AGV controller is defined within an AGV controller class which has an associated process logic that controls the behavior of the AGV controller elements within the class. AGV Controller Class An AGV controller class is an MHS element class. It is a set of AGV controller elements that relate to the same class level set of data, e.g., display geometry, move mode, path mode, process logic. An AGV controller class definition can be saved with the model file, or in a separate file so as to allow its use with different models. AGV Controller Event An AGV controller event is a notification to a controller that some event has occurred involving its AGVs. In general, AGV controller events are processed by the AGV controller and/or associated decision points either with the AGV or with the decision point at which the event occurred. However, the decision point logic can also be defined as a local controller to process the event.

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AGV Decision Point An AGV decision point is an MHS element. It is a location on an AGV path segment and can have associated characteristics. It can have an input and an output connection. At an input connection, one or more parts can be loaded onto an AGV that is at the decision point. At an output connection, one or more parts can be unloaded from an AGV that is at the decision point. An AGV decision point is defined within an AGV decision point class. By default, the behavior of an AGV at an AGV decision point is controlled by the associated AGV controller class process logic. Assignment of process logic at an AGV decision point will override the AGV controller process logic. AGV Decision Point Class An AGV decision point class is an MHS element class. It is a set of AGV decision points that relate to the same class level set of data, e.g., display geometry, controller, decision point logic. An AGV decision point class definition can be saved with the model file, or in a separate file so as to allow its use with different models. AGV Path An AGV path is an arrayed list of AGV path segments and AGV decision points that define how an AGV is going to get to its destination from its current position. The array is dynamic in that as a path segment is exited or a decision point passed, that entity is removed from the AGV path. An AGV path is therefore a temporary and dynamic set of data. It is to be distinguished from an AGV path system. AGV Path System An AGV path system is an element. It consists of a list of AGV segments that defines a layout. It can contain AGV decision points located on AGV segments. An AGV path system is an element and is to be distinguished from an AGV path which is a dynamic data attached to AGV while it is moving. AGV path system is defined within a AGV path system class. AGV Path System Class An AGV path system class is an MHS element class. An AGV path system class can have only one AGV path system element which relates to the class level set of data, e.g., display geometry, maximum speed, direction, etc. An AGV path system class can be saved with a model file or in a separate file so as to allow its use with different models. AGV Segment An AGV segment is an entity. It is a straight line or curve section of AGV path system. AGV segments make up AGV path systems on which AGVs can travel. An AGV decision point must always be located on an AGV segment. An AGV segment is defined within an AGV path system. Aisle An aisle is a representation of a set of racks that are usually contiguous. Racks are made up of bins and are used for storage. This is an advanced modelling term.

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ASRS Abbreviation for Automated Storage and Retrieval Systems. Automated Guided Vehicle (AGV) An AGV is an MHS element. It represents a predefined material handling construct that can transport multiple parts from one AGV decision point to another. AGVs are created within a class. An AGV is defined within an AGV class. The behavior of an AGV is controlled by a combination of its AGV class process logic, working alongside its AGV class AGV controller class process logic and/or by decision point logic for any AGV decision point that it encounters. Batch Control Language (BCL) Batch Control Language (BCL) is a command script language that can be used to build/modify and/or run QUEST simulations. Bay The column number of a column of bins in an aisle. Bins are used for storing the parts. This is an advanced modelling term. Bin A bin is a storage location that can hold one or more parts. This is an advanced modelling term. Buffer A buffer is an element. It is used to represent a storage location for parts in a model. A buffer can have a capacity and a user-defined initial stock level for each part class. A buffer is defined within a buffer class. A buffer element behavior is defined by the associated buffer class process and route logic. Buffer Class A buffer class is an element class. It is a set of buffers that relate to the same class level set of data, e.g., display geometry, maximum capacity, process logic, route logic. A buffer class definition can be saved with the model file, or in a separate file so as to allow its use with different models. Carrier A carrier is an MHS element. Carriers are located and travel on the power and free segments. All carriers belong to a common class that has the common information such as display geometry, capacity, etc. Carrier Class A carrier class is an MHS element class. It is a set of carrier elements that relate to the same class level set of data, e.g., display geometry, stopping space, capacity, etc. A carrier class can be saved with a model file or in a separate file so as to allow its use with different models.

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Class Connections The connection mechanism also includes class connections in a model. When the class connection is defined between two particular classes the parts are routed from one class of elements to another class. Part input logic is normally called to decide the destination of a part to a particular element when the class connections exist between two classes of elements. Connection (Pull and Push) The push connections are the connections between elements/classes to transfer the parts downstream. The two sections (element connections and class connections) refer to push connections. For the propagation of the requests upstream, the pull connections exist between elements and classes. Just as the regular push connection acts as a channel for transferring parts downstream, a pull connection is the conduit for requests traveling upstream in a system. In general, pull connections are made in the reverse order of push connections. However, pull connections are not mandatory. In the absence of a pull connection, the reverse of push connection is used to send requests. Pull connections are useful in sending requests to elements from which a direct push connection to an element does not exist. Similar to the push class connections, pull connections can also be made at the class level. When a request is dispatched to a class, the "Request Input Logic" set on the class decides which element within the class actually receives the request. This logic is executed whenever a request is dispatched to the class. "Request Input Logic" is analogous to "Part Input Logic" for transferring parts. An element class can have pull connections either all at the element level or all at the class. Class and element pull connections cannot be mixed and matched. Conveyor

A conveyor is an element. It is a transportation device that allows parts to move on it. A conveyor has a geometry on which conveyor via points are located that define the direction of flow and the orientation of parts as they move. A conveyor may contain conveyor decision points. A conveyor is defined within a conveyor class. A conveyor behavior is defined by the associated conveyor class process and route logics as well as the process logic of the decision point class of any decision points that are located on the conveyor. Conveyor Class A conveyor class is an element class. It is a set of conveyors that relate to the same class level set of data, e.g., display geometry, maximum capacity, speed, process logic, route logic. A conveyor class definition can be saved with the model file, or in a separate file so as to allow its use with different models. Conveyor Decision Point A conveyor decision point is an MHS element. It is located on a conveyor/extruded conveyor and it has a set of characteristics. It can have an input and/or an output connection. At an input connection, one or more parts can be loaded onto the conveyor. At an output connection, one or more parts can be unloaded from the conveyor. Conveyor decision points are defined within a conveyor decision point

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class. A conveyor decision point is controlled by the decision point logic of its associated conveyor decision point class. Conveyor Decision Point Class A conveyor decision point class is an MHS element class. It is a set of conveyor decision points that relate to the same class level set of data, e.g., display geometry or decision point logic. A conveyor decision point class definition can be saved with the model file, or in a separate file so as to allow its use with different models. Conveyor Via Path Conveyor via path defines the movement and orientation of parts on the conveyor. The length of the via path is usually the length of the conveyor. The conveyor via path is defined between the starting and ending conveyor via points. Additional via points can be added to the via path and their position/orientation can be modified. Conveyor Via Point A conveyor via point is an entity. It is a location on the conveyor. The via path between two conveyor via points determines the position and orientation of a moving part. Coordinate System (Coorsys) Coordinate system is abbreviated to coorsys in most cases. A coorsys is one example of a frame. The term means a set of X, Y, Z axes with a specific location and orientation in space. All geometries have a base coordinate system that is used to manage the mathematical relationships involved in the computer representation of the geometry. On occasion a geometry may have more than one coorsys. Cost Center A cost center is a QUEST element that performs some activity that is of importance to the costing analysis, e.g., a source producing parts. This is an advanced modelling term. Cost Driver The cost driver represents a measure of consumption of some element, e.g., machine utilization in hours. This is an advanced modelling term. Cost Driver Rate The cost driver rate represents the conversion of consumption measure to a cost measure. It converts the cost driver term to a cost measure, e.g., $24 per hour for machine busy time. This is an advanced modelling term. Cost Variable The cost variable represents the source of cost expenditure, e.g., power consumed by a machine based on the machine busy time. This is an advanced modelling term. Crane A crane is an MHS element that moves in an aisle storing and retrieving parts. Cranes are used to carry parts between the pick-up and drop-off stations and the storage bins. This is an advanced modelling term.

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Cycle Process A cycle process is a set of data, usually entered via the GUI, that represents production time (busy state) for a machine. A cycle process has a set of requirements for parts, AGV, and labor that must all be present before the machine starts the cycle process. A cycle process has a time, which can be sampled from a distribution each time the cycle is used that specifies how long the process will take. A cycle process also can specify what parts are produced by the process on its completion. A cycle process can be saved with the model or as a separate file so as to allow its use with other models. A cycle process can be associated with many machines. Daily Schedule The daily schedule is the shift schedule describing the length of the operating shift and the corresponding breaks for a 24-hour period. The daily schedule can be applied to classes to define the time patterns of the operations of the elements of the class. A daily schedule can contain several breaks that define the time breaks that are nonoperational times in a day. Decision Point A decision point is an MHS element. A decision point is either an AGV, power and free, labor or conveyor decision point. Example: AGV Decision Point, Conveyor Decision Point, Labor Decision Point, Power and Free Decision Point. Distributions When modelling a stochastic (random) event inside of QUEST, distributions are used to represent the probability of a given outcome occurring. The distributions available in QUEST are:  Constant Normal Erlang  Uniform Triangular Lognormal  Exponential Poisson Weibull  Gamma Beta QUEST also allows distribution data to be based on a Simulation Control Language (SCL) routine, or a list of values in a file, or a user-defined probability distribution. Drop-Off Station A drop-off station is a location where a crane can drop off a part retrieved from a storage bin. This is an advanced modelling term. Element An element is a subset of the statically created entities used to build a model. An element has a type; e.g., it can be a sink, a source, etc. The term element is also used to include MHS elements which are regarded as a subset of elements. An element is defined within an element class. Parts, which are the dynamic entities of the model, are created, transported, stored, processed, and deleted by different types of elements. Element Class An element class defines a set of related elements. An element class has a type; e.g., it can be a sink class, a source class, etc. The term element class is also used to Rezza Prayogi

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include MHS element classes which are regarded as a subset of element classes. Each element class type has a set of data that is specified at the class level and inherited by its elements. Class process logic and route logic defines the behavior of its elements. Changes to the class level data is immediately inherited by its elements. Some classes can have connections that are termed class connections. Classes with input class connections can have input logic in order to distribute incoming parts between elements of the class. A class definition can be saved with the model file, or in a separate file so as to allow its use with different models. Element Connections The connection is a mechanism to logically connect the elements for the flow of parts in a model. In an element connection an element is connected to another element. The input/output of a particular element are created dynamically as new connections are made. The connections can be made between like entities, i.e., class to a class and an element to an element. Entity Entity describes any physical component of a model. It includes part, element, MHS element, controller, path system, path segment, decision point, group, way point, labor via path, device, coorsys. Extruded Conveyor An extruded conveyor is an element. It can be a straight line or curve section and is created by the layout method. Parts can travel on the extruded conveyor. A conveyor decision point can be located on an extruded conveyor. Extruded conveyors have the same properties and behavior as regular conveyors. Extruded Conveyor Class An extruded conveyor class is an element class. It is a set of extruded conveyor elements that relate to the same class level set of data, e.g., display geometry, maximum capacity, speed, process logic, route logic, shifts, failures, etc. A conveyor class definition can be saved with the model file, or in a separate file so as to allow its use with different models. In all the sections in this sub-chapter relating to conveyors, the reference to conveyor will refer to both the extruded and non-extruded conveyors. Failure Class A failure class represents information on a failure and repair pattern. The failure distribution specifies the time between failures. There is an associated repair process that specifies the time for a repair, by a repair time distribution. Time between failures and time to repair are independent distributions. Multiple failures can occur at the same time. A failure definition can be saved with the model file, or in a separate file so as to allow its use with different models. Failure classes are assigned to element classes that are inherited by individual elements. Frame A frame is an entity. Frames are either way points or coorsys. A frame is really a CAD term. A frame is a location in space (X, Y, Z) and an orientation (yaw, pitch, and roll). A frame is most often used to identify the location and orientation of a geometry in order to allow translation or rotation of the geometry.

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Graphical User Interface (GUI) This is the visual and interactive mechanism by which QUEST models can be built and run. Group A group is an entity. Each group is associated with a group type. It is a collection of elements. A group can be translated or rotated as a single geometric unit. A decision point group can be used to assist in controlling the routing of AGV/labor elements to AGV/labor decision points. A decision point group can have a type and associated data that can be used in AGV/labor routing decisions. Group Type All the groups are assigned to a group type. Users can create their own group types by specifying the name, the entity type the group will hold (elements or AGV decision points) and the association (single/multiple). The association specifies whether single or multiple groups of this type can be assigned to an element. Labor Labor is an MHS element. It represents a predefined material handling construct that can transport multiple parts between the elements and that may be required at elements for a process to be performed. The QUEST labor element resembles the laborers working on the factory floor transferring parts between the elements for various operations and running machines. In QUEST the labor can transport instantaneously (beam) between the elements, delay for a time, and then beam between elements, move smoothly on a labor via path, or move smoothly on a labor path system. Labor is defined within a labor class. The behavior of a labor element is controlled by the process logic of its labor class working alongside the process logic of its labor controller class, together with the process logic of any labor decision point that it encounters. Labor Class A labor class is an MHS element class. It is a set of labor elements that relate to the same class level set of data, e.g., display geometry, speed, process logic. A labor class definition can be saved with the model file, or in a separate file so as to allow its use with different models. Labor Command A labor command is an instruction to a labor element to perform some action normally given by the labor controller. Labor commands are processed in the labor process logic. Users can create their own commands. Labor Controller A labor controller is an MHS element. It is used to globally control one or many labor classes with respect to a set of elements. Each labor class and any labor element can only belong to one labor controller. A labor controller is defined within a labor controller class. The behavior of a labor controller is defined by the process logic of its labor controller class.

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Labor Controller Class A labor controller class is an MHS element class. It is a set of labor controller elements that relate to the same class level set of data, e.g., display geometry, speed, move time mode, process logic. A labor controller class definition can be saved with the model file, or in a separate file so as to allow its use with different models. Labor Decision Point A labor decision point is an MHS element. It is a location on a labor segment and can have associated characteristics. It can have an input and/or an output connection. At an input connection, one or more parts can be loaded onto a labor element that is at the decision point. At an output connection, one or more parts can be unloaded from a labor element that is at the decision point. Labor decision points are defined within a labor decision point class. The behavior of labor at a labor decision point is controlled by default by the associated labor controller's process logic working alongside the associated labor class process logic. A labor decision point's class can also have a process logic, which will override the labor controller class process logic for that labor decision point. Labor Decision Point Class A labor decision point class is an MHS element class. It is a set of labor decision points that relate to the same class level set of data, e.g., display geometry, controller, decision point logic. A labor decision point class definition can be saved with the model file, or in a separate file so as to allow its use with different models. Labor Path A labor path is an arrayed list of labor segments that defines how a labor is going to get to its destination from its current position. The array is dynamic in that as a path segment is exited or a decision point passed, that entity is removed from the labor path. A labor path is therefore a temporary and dynamic set of data. It is to be distinguished from a labor path system. Labor Path System A labor path system is an element. It consists of a list of labor segments that defines a layout. It can contain labor decision points located on labor segments. A labor path system is an element and is to be distinguished from a labor path which is a dynamic data attached to AGV while it is moving. Labor Path System Class A labor path system class is an MHS element class. A labor path system class can have only one labor path system element that relate to the class level set of data, e.g., display geometry, maximum speed, direction, etc. A labor path system class can be saved with a model file or in a separate file so as to allow its use with different models. Labor Point A labor point is an entity. It is a location at each element. An element can have one/or more labor points. When a labor arrives at an element it is placed at the first available labor point.

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Labor Segment A labor path segment is an entity. It is a straight line or curve section of labor path system. Labor segments make up labor path systems on which labor elements can travel. A labor decision point must always be located on a labor segment. A labor segment is defined within a labor path system. Labor Via Point A labor via point is an entity. It is a location in space that determines a moving labor element's position and orientation. Lane A lane is a path for a crane to move along, usually between two facing racks. This is an advanced modelling term. Load Process A load process is a set of data, usually entered via the GUI, that represents loading time for an element that supports loading. A load process has a time, which can be sampled from a distribution each time the process is used, that specifies how long the process will take if not interrupted. A load process can be saved with the model or as a separate file so as to allow its use with other models. Logic Logic is the name for simulation rules written in Simulation Control Language (SCL). Logic is distributed among the elements in the model. Logic governs the behavior of the model. Many common logics are predefined and their SCL is provided. Users may write their own logic using SCL. Machine A machine is an element that behaves much as a physical machine does. It can use parts, labor, or AGVs to perform a time-taking cycle process that produces parts. It can undergo setups, breakdowns, and repair, as well as processing parts. A machine is defined within a machine class. The behavior of a machine is controlled by the data, process, and route logic of its associated machine class. Machine Class A machine class is an element class. It is a set of machine elements that relate to the same class level set of data, e.g., display geometry, process logic, associated processes. A machine class definition can be saved with the model file, or in a separate file so as to allow its use with different models. MHS Abbreviation for Material Handling System. MHS Element MHS element describes a subset of elements such as AGVs, labor, carrier. MHS Element Class An MHS element class contains MHS elements of the same type as the MHS element class. The elements within a class have a set of data that they all use, e.g., geometry, logic. MHS element class is a subset of element class. MHS element

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class data can be saved with the model file or separately so as to allow its use with other models. MHS Template The MHS template is a set of attributes for a MHS/crane. This is an advanced modelling term. Multi-day Schedule This schedule is a collection of daily schedules. The user has the option of creating different daily schedules and then creating a multi-day schedule with the daily schedule attached to the particular day. To create a multi-day schedule at least one daily schedule must be defined. Part A part is an entity that is created dynamically as the simulation runs. It moves between elements and is processed by the system. Parts are usually generated at sources or as a result of a machine process. Parts are usually destroyed by the sinks or as a result of a machine process. Parts are the entities in a discrete-event model which receive "services" from elements, or are "processed" by them. Parts are the material and/or information flowing through the system over time and are explicitly represented by geometries. Part classes which specify various attributes, such as appearance and priority, may be defined by the user. Part classes are created during the model build phase. Parts are created and destroyed during the model run phase. A part class definition can be saved with the model file, or in a separate file so as to allow its use with different models. Part Class It is a set of parts that relate to the same class level set of data, e.g., geometry. A part class definition can be saved with the model file, or in a separate file so as to allow its use with different models. Pick-Up Station The pick-up station is the location where the crane can collect a part to be stored. Pick-up stations are usually modeled as buffers. This is an advanced modelling term. Power and Free Class A power and free class is an MHS element class. A power and free class can have only one P&F element that relates to the class level set of data, e.g., display geometry, speed, dog spacing, shifts, failures, etc. A power and free class can be saved with a model file or in a separate file so as to allow its use with different models. Power and Free Decision Point A power and free decision point is an MHS element. It is a location on a power and free segment and can have associated characteristics. It can have an input and/or an output connection. At an input connection, one or more parts can be loaded onto a carrier that is at the decision point. At an output connection, one or more parts can be unloaded from a carrier that is at the decision point. A power and free decision

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point is defined within a power and free decision point class. The behavior of a power and free decision point is controlled by the process logic of the associated power and free decision point class. Power and Free Decision Point Class A power and free decision point class is an MHS element class. It is a set of power and free decision points that relate to the same class level set of data, e.g., display geometry, process logic. A power and free decision point class definition can be saved with the model file, or in a separate file so as to allow its use with different models. Power and Free Segment A power and free segment is an entity. It is a straight line or curve section of power and free system. Power and free segments make up power and free systems on which carriers can travel. A power and free decision point must always be located on a power and free segment. A power and free segment is defined within a power and free system. Power and Free System A power and free system (sometimes referred to as P&F) is an element. It is an arrayed list of power and free segments that defines a network of power and free segments. Power and free decision points and carriers are located in the P&F system. Process A process is a set of data, usually entered via the GUI, that controls time-taking activities for model elements. There are different types of processes: cycle, load, unload, repair, setup. A process can be assigned to more than one element classes. A process definition can be saved with the model file, or in a separate file so as to allow its use with different models. A process definition includes part/AGV/labor requirements, process time, and products. Rack A rack is a set of bins used for storing the parts. This is an advanced modelling term. Repair Process A repair process is a set of data, usually entered via the GUI, that represents repair time for an element. A repair process has a time, which can be sampled from a distribution each time the process is used, that specifies how long the process will take. A repair process can be saved with the model or as a separate file so as to allow its use with other models. Each repair process is associated with a Failure class. Setup Process A setup process is a set of data relating to a setup on a machine. A setup process operates on a machine. It can be assigned to be triggered before a cycle process depending on which cycle process has just been completed and upon which cycle process is about to start. A setup process can be saved with the model or as a

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separate file so as to allow its use with other models. Setup processes are associated with machine classes. Shift A shift is a set of data that defines an availability pattern over time that specifies when an element class is available to perform work. Shift can be defined as a daily or a multiday schedule. Daily schedules are made up of shift breaks; multiday schedules are made up of daily schedules. Simulation Control Language (SCL) Simulation Control Language (SCL) is a programming language that can be used to make a running model behave according to the logical rules in the SCL program. Sink A sink is an element. It can operate in a push or in a pull mode. In a push mode, it is a passive element, receiving parts, deleting them from the simulation and generating statistics. In a pull mode, a sink can generate requests for parts based on an interrequest time (IRT). In this mode, a sink can have a maximum number of part requests and a start time for its first request. A sink has a process logic but no route logic. A sink is defined within a sink class. The behavior of a sink is controlled by the process of its sink class. Sink Class A sink class is an element class. It is a set of sinks that relate to the same class level set of data, e.g., geometry, push/pull mode, logics. A sink class can be saved with the model or as a separate file so as to allow its use with other models. Source A source is an element. It can operate in a push or in a pull mode. In a pull mode, it is a passive element, receiving part requests, creating the parts as requested, entering them into the simulation and generating statistics. In a push mode, a source can generate parts based on an inter-arrival time (IAT). In this mode a source can be constrained to the creation of a maximum number of parts and a start time for its first part creation. A source has process logic and route logic. The behavior of a source is controlled by the process and route logic of its source class. Source Class A source class is an element class. It is a set of sources that relate to the same class level set of data, e.g., geometry, push/pull mode, logics. A source class can be saved with the model or as a separate file so as to allow its use with other models. Stack Point A stack point is an entity. It represents a location in space where parts can stack. Each element has a stack point where the parts are placed after animation. Storage Class A storage class is a set of storage domains to which part class storage rules can be applied. This is an advanced modelling term.

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Storage Domain A storage domain is a set of bins to which common storage rules can be applied. This is an advanced modelling term. Stream (Random Number Stream) QUEST allows the user to create an unlimited number of random number streams. These streams can be referenced whenever a stochastic (random) probability distribution is applied. The default setting for QUEST is 10 random number streams. Tier A tier is the row number of a row of bins in an aisle. This is an advanced modelling term. Unload Process An unload process is a set of data, usually entered via the GUI, that represents unloading time for an element class. An unload process has a time (which can be sampled from a distribution each time the process is used) that specifies how long the process will take. An unload process can be saved with the model or as a separate file so as to allow its use with other models. User Interrupts User interrupts are user-defined interrupts that may be scheduled to occur during simulation run time. The interrupt may be raised for any element in the QUEST model. With this mechanism, elements may be interrupted from their current operation and instructed to perform some other task. For example, a machine that is busy processing, i.e., busy executing a work statement, may be interrupted in the middle of the work, and instructed to execute some other process. Via Point A via point is an entity. It represents a location in space that determines a moving element's position and orientation. There are two types of via points - labor and conveyor. Way Point Way points are entities that represent a three-dimensional point in space along with an orientation (X, Y, Z, yaw, pitch, and roll). Way points do not exist freely, they are associated with an element or a path. A way point is a type of frame. Way points come in several varieties, each with a specific purpose and display characteristic for identification purposes. The way points in the system are: stack points, via points, labor points.

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APPENDIX II CAD MODELING TERMS The terms are not listed alphabetically but are presented in a manner which builds on information. Vertex A vertex is an X, Y, Z coordinate that is stored in the database. It is the fundamental primitive entity from which all other entities are composed. Point A point may or may not be a vertex. In many functions, when prompted to indicate a point, the current "Indicate Point Mode" determines what may be indicated. For example, a location along an edge might be chosen, or an arbitrary location on a surface might be chosen, regardless of the existence of a vertex at that location. Splat A splat is a three-dimensional cross hair that provides feedback when a point or vertex is indicated. Line A line is a straight segment connecting two vertices and is represented on the screen as "wireframe". Mathematically, a line has no area. Polygon A polygon is a bounded plane defined by an ordered set of vertices lying in the plane. It must be convex and may have up to 128 sides. Edge The edge forms the boundaries of a polygon and may be free or shared by two polygons. Polyline A polyline is as a set of connected line segments in the same subobject that terminates at a fork, or at a segment whose interior angle (formed with the previous segment) is less than the minimum interior angle specified in the CAD modes function. The term polyline specifically refers to connected lines that are not part of a B-spline curve entity. Certain CAD context functions utilize the concept of a polyline, such as Del Line and Mov Line. Curve A curve is any connected set of lines. These may be a polyline, or the "flesh" of a Bspline curve. A B-spline curve is a mathematical definition of a spatial curve that is represented by line segments. B-splines in QUEST are "NURBS" (Non Uniform Rational B-splines), and may be manipulated in ways different from polylines. Bsplines may be rebuilt to finer or coarser display levels, and may be frozen into polylines. Any function referring to a curve will allow the selection of a B-spline or a polyline. Most functions will use the exact mathematical curve when a B-spline is

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selected. Some functions may only use the line segment information, ignoring the B-spline information. Surface A surface can be either a polygon or NURBS-based mathematical surface represented with polygonal facets. As with curves, functions in the system automatically perform the appropriate type of evaluation based on the type of surface selected. The only time a distinction is made is for certain functions that are polygon specific, such as Del Poly and when snapping with "Center On Polygon = YES". Vector Vectors are not geometric entities but are used by certain functions in a transient fashion. They are characterized by a direction (three numbers), and a magnitude. Axis An axis is similar to a vector except that there is no magnitude. Plane A plane is a non-geometric entity and is used in a transient manner. It is characterized by a direction (three numbers - A, B, C) and an offset from the origin (D). These four numbers define a locus of points in space satisfying the equation: Ax + By + Cz + D = 0. Coorsys A coorsys represents a three-dimensional point in space along with an orientation. A coorsys is created, manipulated, and deleted from the CAD context. (A coorsys cannot be manipulated from any other context.) A coorsys is used for attaching one part to a second part when creating devices. They can also be used to define the positioning of way points on objects created in the CAD world and introduced (through creation or modification of elements) in the model world. When element geometry is introduced into the model, the translational and rotational position of the coorsys defines the default position of the way point. Base Coorsys Each object (defined below) has one coorsys called its base coorsys. All geometric entities composing the object are defined relative to this coordinate system and object manipulations occur with respect to it. Text Text is represented with wireframe rendering in a font provided by DELMIA. It is a special kind of geometric entity and should not be confused with other forms of text in the system. Subobject A subobject is an arbitrary collection of polygons, lines, surfaces, curves, and text. For example, when a block is created using the CAD | Create | Create | Block button, an object is created that contains one subobject, which in turn contains the polygons making up the block. If the block is then cut, there will be two new

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objects, each with one subobject. If the cut block is merged, there will be one object, but it will now contain two subobjects. Object An object is an entity that is typically created in the CAD context and is composed of subobjects and coorsys. All objects in the CAD world are automatically merged together and saved as a single part when save is executed from CAD. Part Parts are named entities that are typically created in the CAD context when save is executed. CAD parts are used as building blocks when creating a device. This CAD part is to be distinguished from the part defined while building a QUEST model. Device Devices are named entities that are created automatically when elements are created, or are imported from DELMIA's other products (IGRIP, VNC, etc.). Devices in QUEST are generally single parts; devices imported from IGRIP (via a QUESTCELL) may be multiple, possibly moving parts. Most QUEST elements are single devices; however, machines may be multiple devices depending on the definition of the element. Joints, Links, DOFs Joint refers to the axis of motion between rigid links, which are parts. Each joint is a degree-of-freedom (DOF). The Model | Kin page is used to create multiple DOF elements in QUEST.

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