Name typical types of areas of a factory (9)
R&D
Goods Receipt
Warehouse
Production
Shipping
Administration
Maintenance
Parking lots
Canteen
What are the three main types of building structures
Multi-story buildings
Flat buildings
Hall buildings
Name general regulation and rules for planning a factory structure (5)
State building code
building use ordinance
fire protection ordinance
Trade regulations
Energy efficiency directives
How can productive areas be structured? (3, with examples)
Function- or task-oriented, e.g. workshop production
Process- or procedure-oriented, e.g. batch production, paint shop
Product-oriented, e.g. flow production, BMW assembly line
“Which area should be placed where?” - possible targets (6)
low transport volume
low inventories
low throughput times
reduction of product damage
easy material flow and material flow control
few jams
“Which area should be placed where?” - possible constraints (8)
Available space
load capacities
logistics requirement
availability of supply technology
Room heights
Resident protection
Maintenance possibilities
Investment volume
Explain the facility layout problem and possibilities to solve it
Real-world conditions impose many different requirements on the “Facility Layout Problem”. Therefore, a solution method is either explicitly tailored to the special case or neglects the problems of the individual case.
Due to the amount of possibilities in layout planning, mathematical optimization tools are used.
What is the current trend in layout planning?
Share of Brownfield planning increases
What characterizes Brownfield planning?
Strongly limited by restrictions
Solution space limited to a few solution alternatives (because of BC)
Solution alternatives differ significantly from each other in their properties (because of BC, mixed solutions not possible)
What method is popular in finding the ideal brownfield layout?
Material flow simulation for comparison of alternatives
Name 2 advantages and 2 disadvantages of material flow simulation
Advantage:
Reliable comparison data
Visualization allows checking for plausibility
Disadvantages:
High modeling effort
No automatic optimization
Describe the steps from ideal layout to block layout (3)
Create ideal layout
Merging the operating areas into a building grid —> Facility plan vs. ideal block layout
Compliance with the ideal allocation whenever possible —> Block Layout
Name the planning steps from rough layout to detailed layout
Optimization of the machine arrangement
Supply and disposal
Workplace design
fine layout of the operating areas
Machine set-up
Selection of the operating equipment
What would be the idea goal in factory planning?
Goal: real planning equals ideal planning
Reality sets a lot of boundary conditions
Name and explain the 3 target systems in the general factory planning process and their relationship
Structure planning (plant and facility structure)
Rough layout planning (area structure)
Detailed layout planning (resource structure)
Each contains an ideal and real planning. They are constitutive and connected trough evaluation (forward) and iterations (backward).
Name 3 input parameters for the planning task and there general usage
production program
bill of materials
workflow (assembly precedence graph)
The basis for all planning activities is an analysis of all the data on which the factory planning task is based.
What kind of target systems exist, and where can they be derived from?
The specifications derive from company goals, such as flexibility (capacity, organization, procedure), economic efficiency (utilization rate, value creation, inventories) or attractivity (environmental impact, appearance, work design).
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