生產(chǎn)運作管理之設(shè)施設(shè)計課件

生產(chǎn)與運作管理

ProductionandOperations

Management第二章設(shè)施設(shè)計DesignofFacilities第二章設(shè)施與作業(yè)設(shè)計

（DesignofFacilitiesandJobs）設(shè)施位置選擇（FacilityLocation）

設(shè)施布置（FacilityLayout）*作業(yè)設(shè)計（JobDesign）

第一節(jié)設(shè)施位置選擇（FacilityLocation）設(shè)施位置決策（Decision）設(shè)施位置選擇的因素（Considerations）設(shè)施位置分析方法（Methods）InGeneral-LocationDecisionsLong-termdecisionsDifficulttoreverseAffectfixed&variablecostsTransportationcostAsmuchas25%ofproductpriceOthercosts:Taxes,wages,rentetc.Objective:MaximizebenefitoflocationtofirmIndustrialLocationDecisionsCostfocusRevenuevarieslittle

betweenlocationsLocationisamajor

costfactorAffectsshipping&

productioncosts(e.g.,labor)Costsvarygreatlybetween

locationsServiceLocationDecisionsRevenuefocusCostsvarylittlebetweenmarketareasLocationisamajor

revenuefactorAffectsamountof

customercontactAffectsvolumeof

businessLocationDecisionSequenceCountryRegion/CommunitySiteFactorsAffectingLocation資源（人力、原材料、能源、資本、土地的價格及其供應(yīng)狀況）運輸（費用及其設(shè)施狀況）市場（需求量、結(jié)構(gòu)、競爭、價格、顧客分布及其需求特點）建筑（費用及其條件）；稅收、保險（種類、政策及其水平）；自然條件（氣候、地理位置、地質(zhì)狀況）；經(jīng)濟條件（基礎(chǔ)設(shè)施、生活質(zhì)量）；社會條件（文化習(xí)俗、公眾態(tài)度）；政治條件（政府政策及其態(tài)度、政治穩(wěn)定）。LocationEvaluationMethodsFactor-ratingmethodLocationalbreak-evenanalysisCenterofgravitymethodTransportationmodelFactor-RatingMethodMostwidelyusedlocationtechniqueUsefulforservice&industriallocationsRateslocationsusingfactorsIntangible(qualitative)factorsExample:Educationquality,laborskillsTangible(quantitative)factorsExample:Short-run&long-runcostsExample：FactorRatingMethodMethodofcost-volumeanalysisusedforindustriallocationsStepsDeterminefixed&variablecostsforeachlocationPlottotalcostforeachlocationSelectlocationwithlowesttotalcostforexpectedproductionvolumeMustbeabovebreak-evenLocationalBreak-EvenAnalysisLocationalBreak-EvenAnalysisExampleYou’’reananalystforACDelco.You’’reconsideringanewmanufacturingplantinAkron,BowlingGreen,orChicago.Fixedcostsperyearare$30k,$60k,&$110krespectively.Variablecostspercaseare$75,$45,&$25respectively.Thepricepercaseis$120.Whatisthebestlocationforanexpectedvolumeof2,000casesperyear?LocationalBreak-EvenCrossoverChart050000100000150000200000050010001500200025003000VolumeAnnualCostAkronChicagoBowlingGreenAkronlowestcostBowlingGreenlowestcostChicagolowestcostCenterofGravityMethodFindslocationofsingledistributioncenterservingseveraldestinationsUsedprimarilyforservicesConsidersLocationofexistingdestinationsExample:Markets,retailersetc.VolumetobeshippedShippingdistance(orcost)Shippingcost/unit/mileisconstantCenterofGravityMethodStepsPlaceexistinglocationsonacoordinategridGridhasarbitraryorigin&scaleMaintainsrelativedistancesCalculatex&ycoordinatesfor‘‘centerofgravity’GiveslocationofdistributioncenterMinimizestransportationcostMinimizestransportationcostCenterofgravityExamplexy(x*,y*)2000100010002000x*=66.7y*=93.3TransportationModelFindsamounttobeshippedfromseveralsourcestoseveraldestinationsUsedprimarilyforindustriallocationsTypeoflinearprogrammingmodelObjective:Minimizetotalproduction&shippingcostsConstraintsProductioncapacityatsource(factory)DemandrequirementatdestinationExample：TransportationModel在S4的最優(yōu)結(jié)結(jié)果在S5的最優(yōu)結(jié)結(jié)果在S6的最優(yōu)結(jié)結(jié)果最優(yōu)廠址址S4———34698S5———34867S6———34818S4：最最優(yōu)廠址址第二節(jié)設(shè)施布置置（FacilityLayout）布置的目目標(Objectives)布置的類類型(Type)布置的方方法(Methods)WhatisFacilityLayoutLocationorarrangementofeverythingwithin&aroundbuildingsObjectivesaretomaximizeCustomersatisfactionUtilizationofspace,equipment,&peopleEfficientflowofinformation,material,&peopleEmployeemorale&safetyConstraintsonLayoutObjectivesProductdesign&volumeProcessequipment&capacityQualityofworklifeBuildingandsite重新布置置的具體體原因(Reasons)（１）低低效率的的作業(yè)（（例如，，高費用用、瓶頸頸）。（２）安安全事故故或危險險。（３）新新產(chǎn)品或或服務(wù)的的引進。。（４）產(chǎn)產(chǎn)品或服服務(wù)設(shè)計計的變化化。（５）新新工藝藝的引進進，原有有工藝的的改進。。（６）產(chǎn)產(chǎn)量或或產(chǎn)品組組合的變變化（７）方方法或或設(shè)備的的變化。。（８）環(huán)環(huán)境或或其他法法規(guī)要求求的變化化。（9））士氣氣問題（（例如，，缺乏面面對面的的接觸））。布置的基本類類型(BasicTypeofLayouts)Process-orientedlayoutdealswithlow-volume,high-varietyproduction(“jobshop”,intermittentproduction)Product-orientedlayoutseeksthebestpersonnelandmachineuseinrepetitiveorcontinuousproductionFixed-positionlayoutlargebulkyprojectssuchasshipsandbuildings面向過程布置置(Process-OrientedLayout)按加工處理的的工藝性質(zhì)分分別設(shè)置相應(yīng)應(yīng)的生產(chǎn)單位位，使產(chǎn)品或或顧客依次經(jīng)經(jīng)過相應(yīng)的各各生產(chǎn)單位接接受所需的特特殊的加工處處理或服務(wù)。。一個生產(chǎn)單位位是一種工藝藝性質(zhì)的設(shè)備備、工人等的的集合體，進進行一種工藝藝性質(zhì)的加工工處理或服務(wù)務(wù)。它能處理各種種具有不同加加工要求的但但加工性質(zhì)相相同的產(chǎn)品或或服務(wù)。面向產(chǎn)品布置置(Product-OrientedLayout)按產(chǎn)品或顧客客的性質(zhì)分別別設(shè)置相應(yīng)的的生產(chǎn)單位，，使某種產(chǎn)品品或顧客在一一個生產(chǎn)作業(yè)業(yè)單位里的得得到所需的幾幾乎全部的加加工或服務(wù)。。一個生產(chǎn)作業(yè)業(yè)單位是多種種工藝性質(zhì)的的設(shè)備、工人人等的集合體體，進行規(guī)定定的各種工藝藝性質(zhì)的工或或處理。它是借助于高高度標準化的的產(chǎn)品或服務(wù)務(wù)及其所需用用的高度標準準化的作業(yè)得得以實現(xiàn)的。。一項工作被被劃分成一系系列的標準作作業(yè)，以實現(xiàn)現(xiàn)勞動和設(shè)備備的專業(yè)化。。固定位置布置置(Fixed-PositionLayout)產(chǎn)品或項目的的位置保持不不變，而人員員、物料和設(shè)設(shè)備在需要時時移動的布置置。它與面向產(chǎn)品品布置和面向向工藝（過程程）布置截然然相反，是人人員、物料和和設(shè)備向“產(chǎn)產(chǎn)品”移動，，而不是相反反。產(chǎn)品的特點決決定了這種布布置，大的重重量、尺寸、、體積、以及及其他因素致致使產(chǎn)品或?qū)ο蟛贿m宜或或極其難以移移動，而必須須采用這種布布置方式。JobShopLayoutEmergencyRoomLayoutSurgeryRadiologyE.R.bedsPharmacyBilling/exitE.R.TriageroomE.R.AdmissionsPatientB-erraticpacemakerPatientA-brokenlegHallwayRepetitiveLayout13245WorkOfficeBeltConveyorWorkStationNote:5tasksoroperations;3workstationsWorkStationStationStepsinDevelopinga

Process-OrientedLayoutConstructa“from-tomatrix”DeterminespacerequirementsforeachdepartmentDevelopaninitialschematicdiagramDeterminethecostofthislayoutBytrial-and-error(ormoresophisticatedmeans),trytoimprovetheinitiallayoutPrepareadetailedplanthatevaluatesfactorsinadditiontotransportationcostCostofProcess-OrientedLayout面向工藝布置置，按已設(shè)計計的工藝流程程，根據(jù)工藝藝性質(zhì)的不同同，劃分出若若干個生產(chǎn)單單位，然后確確定各生產(chǎn)單單位的相對空空間位置。主要問題：確確定各生產(chǎn)單單位的相對位位置，使其相相互之間的總總運輸量或費費用最小，即即InterdepartmentalFlowofParts:from-tomatrix12345612345650100002030501002001005000PossibleLayout1Room1 Room2 Room2Room4 Room5 Room6InterdepartmentalFlowGraphShowingNumberofWeeklyLoads11005030102050201005023456C=(50+200+40)+(30+50+10)+(40+100)+(50)=$570PossibleLayout2Room1 Room2 Room2Room4 Room5 Room6InterdepartmentalFlowGraphShowingNumberofWeeklyLoads21005030102050201005013456C=(50+100+20)+(60+50+10)+(40+100)+(50)=$480ComputerProgramstoAssistinLayoutCRAFTSPACECRAFTCRAFT3-DMULTIPLECORELAPALDEPCOFADFADES-expertsystemRelationshipChart1PresidentO2CostingUAA3EngineeringIO4President’sSecretary1234A=AbsolutelynecessaryE=EspeciallyimportantI=ImportantO=OrdinaryU=UnimportantX=NotDesirableProduct-OrientedRequirementsStandardizedproductHighproductionvolumeStableproductionquantitiesUniformqualityofrawmaterials&componentsProduct-OrientedLayoutTypesAssemblesfabricatedpartsUsesworkstationRepetitiveprocessPacedbytasksBalancedbymovingtasksBuildscomponentsUsesseriesofmachinesRepetitiveprocessMachinepacedBalancedbyphysicalredesignFabricationLineAssemblyLineAssemblyLineBalancingAnalysisofproductionlinesNearlyequallydividesworkbetweenworkstationswhilemeetingrequiredoutputObjectivesMaximizeefficiencyMinimizenumberofworkstationsAssemblyLineBalancingSteps1. Determinetasks(operations)2. Determinesequence3. Drawprecedencediagram4. Estimatetasktimes5. Calculatecycletime6. Assigntasks7. Calculatenumberofworkstations8. CalculateefficiencyAssemblyLineBalancingEquationsCycletime,CT=Productiontimeavailable

DemandperdayMinimumnumberofworkstationsTasktimesCycletimeNmin=Efficiency,BE=Tasktimes*(Cycletime)(Actualnumberofworkstations)BalanceDelay,BD=1—Tasktimes*(Cycletime)(Actualnumberofworkstations)可行的作業(yè)分分配分配給每個工工作地的作業(yè)業(yè)，必須：（1）滿足作作業(yè)之間的優(yōu)優(yōu)先(precedence)關(guān)系系；（2）分配給給每個工作地地的作業(yè)的時時間之和必須須不大于周期期時間。LayoutHeuristicsforAssigningTasksinAssemblyLineBalancingLongesttasktime-choosetaskwithlongestoperationtimeMostfollowingtasks-choosetaskwithlargestnumberoffollowingtasksRankedpositionalweight-choosetaskwherethesumofthetimesforeachfollowingtaskislongestShortesttasktime-choosetaskwithshortestoperationtimeLeastnumberoffollowingtasks-choosetaskwithfewestsubsequenttasksRandom–choosetaskrandomlyExampleTaskABCDEFGHITime(min.)1011541237113Taskmustfollow--ABBAC,DFEG,HABEHCDFGI10Min.51112373411480productivemin.,complete40units,eachday.ExampleExampleC=12min.LongesttasktimeABEHCDFGI10Min.51112373