Long-Range Capacity Planning and Facility Location

Example: Armstrong Pumps

• Line Balancing – Network (Precedence) Diagram

• A

• C

• B

• E

• D

• F

Example: Armstrong Pumps

• Line Balancing – Cycle Time
• = 45/10 = 4.5 minutes per pump

Example: Armstrong Pumps

• Line Balancing – Minimum Number of Workstations
• Minimum
• Number of
• Workstations
• = [(42.8)(10)]/45 = 9.51 workstations

Example: Armstrong Pumps

• Line Balancing – Incremental Utilization Heuristic
• WS Tasks Mins./pump #WS’s Incr.Util.
• 1 A 5.4 5.4/4.5=1.2= 2 60.0%
• 1 A,B 5.4 + 3.2 8.6/4.5=1.9= 2 95.0%
• 1 A,B,C 8.6 + 1.5 10.1/4.5=2.2= 3 49.8%
• 2 C 1.5 1.5/4.5=.33= 1 33.3%
• 2 C,D 1.5 + 2.8 4.3/4.5=.96= 1 95.6%
• 2 C,D,E 4.3 + 17.1 21.4/4.5=4.8= 5 95.1%
• 3 E 17.1 17.1/4.5=3.8= 4 95.0%
• 3 E,F 17.1 + 12.8 29.9/4.5=6.6= 7 94.9%
• 4 F 12.8 12.8/4.5=2.8= 3 94.8%

Example: Armstrong Pumps

• Line Balancing – Utilization of Production Line
• = 9.51/10 = .951 = 95.1%

Planning Product Layouts

• Rebalancing a Production Line
• Changes that can lead to production lines being out of balance or having insufficient/excess capacity are:
• Changes in demand
• Machine modifications
• Variations in employee learning and training

Planning Cellular Manufacturing Layouts

• Cell Formation Decision
• Which machines are assigned to manufacturing cells
• Which parts will be produced in each cell

Planning Cellular Manufacturing Layouts

• Fundamental Requirements for Parts to be Made in Cells
• Demand for the parts must be high enough and stable enough that moderate batch sizes of the parts can be produced periodically.
• Parts must be capable of being grouped into parts families.