Cs Porting

This case study focuses on the redesign of the M Porting Company's production facility to improve efficiency and accommodate increased demand for their photographic equipment storage cannisters. Key tasks include analyzing production times, creating a part-machine matrix, revising handling methods, and developing a new cellular layout. The final report will summarize the analysis, layout alternatives, and the methodology used in the redesign process.

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Cs Porting

Uploaded by

John Lyyah Delgado

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Facility Layout Design Case Study

M Porting Detailed Layout

Title: Facility Layout Design Case Study: M Porting Detailed Layout

Date approved for distribution: March 15, 2000 Author:

Thomas Lacksonen, Associate

Professor
Department of Industrial Management
University of Wisconsin-Stout
Menomonie, WI 54751

Warning: This document may be duplicated for instructional use within the
institution purchasing the case. Other duplication is prohibited.

Keywords: Production/manufacturing
Layout design - detailed
Capacity analysis
Group technology

Abstract: This case study involves the detailed re-design of an existing production facility. Students
must analyze capacity requirements for one type of equipment. Students must perform group
technology analysis to identify cells to make the different types of parts. Students must identify
a material handling solution for one material flow. Students must determine transfer batch sizes
and work-in-process storage requirements in a cellular layout. Students must do a flow analysis
using their revised designs. Upon completing these analyses, the students must do a complete
CAD redesign of the facility and create a report to justify their solution.

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Introduction:

Donnie and Donna Miller started the M Porting Company two years ago when they both
finished college. Donna is an avid amateur photographer who was not satisfied with the
functionality or durability of existing photographic equipment storage cannisters. Her
new husband Donnie developed a new cannister as a project in his Senior Product Design
class. Donna, a marketing major, was so impressed she decided that after graduation they
would start their own company manufacturing cannisters for cameras and other bulky
equipment. Thus M Porting was created.

With help of a small business loan, Donna and Donnie acquired a 2400 square foot space
in the local industrial park and filled it with used manufacturing equipment. Donnie
refined the design to improve manufacturability and Donna got the local camera stores to
sell the cannisters.

Manufacturing process description:

M Porting Co. manufactures a variety of fabric covered metal cannisters used to transport
cameras, survey equipment, and other bulky equipment. There are two basic types of
cannisters. The Standard Cannister consists of an aluminum main body, an aluminum
hinged lid, a canvas cover, and a canvas carry strap. A second Discount Cannister is the
same as the Standard Cannister except that the hinged lid is replaced by a flat lid. Other
product variations including size and color differences are not detailed because the
products have the same routings and production times. Indented bills of materials
showing all significant production parts for the two products are shown in Figure 1.
Table 1 shows the route sheets for all manufactured parts. The setup and cycle times are
believed to be accurate within 10%. Variability of these times is not know precisely, but
is not believed to be a significant problem.

The top and bottom ends are the two subassemblies. Each is made by pressing aluminum
sheets into a shallow cup shape and drilling holes in the sides. The subassemblies are
currently made and handled in lots of 10 to minimize setup cost and to facilitate worker
training.

The main body and hinged lid are made from 20 foot long aluminum tubes, which are
cut to length at the cutoff saw. One tube typically produces 4 bodies and 4 lids. The lid
piece is also cut in half to produce two halves which fold over the sides of the cannister
body. Holes are drilled in the side of the main body and in the sides and top of the
hinged lid. Then a top end is riveted to the hinged lid and a bottom end is riveted to the
main body. The parts are then sent to one of two identical assembly stations where
hardware and linings are attached. The flat lids are made by pressing aluminum sheets
into a cup shape and then by assembling linings and hardware to the aluminum piece.

The carry strap and cover are made from canvas. Canvas is brought in rolls to the
cutting table. The fabric spreading and pattern designs permit all pieces for up to 50
units to be

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cut at one time. The kits of pieces are sent to outside contractors where they are sewn
together, still in lots of up to 50.

The four assemblies (main body, one lid, carry strap, and cover) are taken to the pack
area and stored on open shelves. When orders are received, the four assemblies are
collated into a finished product, packed, and shipped. Currently all products are made to
order in batches for specific stores. It is anticipated that when individual mail orders
arrive based on the magazine ads, the components can be individually made, but still
collated at the packing and shipping station.

Problem description:

The current facility layout is organized more for product development than for
production. As equipment was purchased, the layout evolved with processing equipment
on the north side and assembly areas on the south side of the factory floor. See Figure 2
for a CAD drawing of the existing layout (also available as a DWG file). Table 2 gives
dimensions of key items in the drawing and Table 3 gives the current sizes of each
workstation.

This month Donna has placed a series of ads in a national photography magazine.
Donnie has designed a cannister specifically to hold surveying equipment. Both expect
a significant increase in production demand in the next six months, leveling off at 1000
Standard Cannisters and 500 Discount Cannisters per month. They realize that there
must be significant changes made to the production system for the company to remain
profitable.

The first change will be to bring all sewing operations into their facility. Currently they
have two sewing machines used primarily for product development and occasional
rework. Production canvas is received, inspected, and then cut on the fabric cutter. The
kits of pieces are then sent to subcontractors who do sewing out of their homes.
Completed assemblies are returned to the factory and sent to packing, where they are
collated with the other assemblies prior to shipment. Donna believes that bringing the
sewing operations into the factory should reduce kitting labor, eliminate kit and assembly
transportation cost, and reduce product lead times. She plans to purchase one additional
machine to meet the forecast demand.

The second change will be to improve the handling of aluminum tubes. Currently the 20
foot tubes are carried in by hand using three workers, and set on a table in front of the
saw. The saw operator must stand in the aisle to load and run the parts. Donnie believes
that there is a safer way to handle the tubes and is willing to invest in a better handling
method. M Porting currently owns a pallet jack and shares a fork truck with the small
business adjacent to them. The fork truck has a boom attachment to carry the canvas
rolls. The pallet jack is used in shipping and receiving and to carry totes of parts and
assemblies between workstations. These methods may change as the layout is
redesigned. Table 1 also shows the current handling methods and transfer batch sizes for
each part.

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The third and most significant change is to convert the facility to a cellular
manufacturing layout. Currently products are built in batches to match store orders.
Donnie believes that the parts can be separated into two families, each made in their own
manufacturing cell. Manufacturing cells will better handle the increased demand and
increased product variations (sizes and colors) without excessive handling costs. Donnie
also hopes that they will be able to transfer parts in batch sizes of one within the cells.
This will reduce work-in-process inventory, reduce storage space requirements at the
workstations, and improve quality. The conversion will require the movement of several
machines.
Fortunately, the building has necessary utilities throughout its manufacturing space
and all of the machines are easily moved. Donnie believes that the relocation can be
completed in a few days with their existing workers.

Assignment:

1. Analyze the production times of the sewing operations and recommend the number
of sewing machines to purchase.
2. Create a part-machine matrix and divide the manufactured parts into two
families. Identify the machines in the manufacturing cells for each family.
3. Revise the handling methods and identify the new transfer batch sizes for
each handling step. Where possible, reduce the number of storage locations at
workstations. Summarize the results by updating Table 1.
4. Create a flow-between matrix based on the routings in Table 1. Use the matrix to
find a good arrangement of workstations and to estimate flow cost of your new
layout.
5. Create a revised detailed layout of the entire facility, showing the structure (walls,
columns, doors, docks), processing equipment, storage equipment and locations,
and handling aisles. Evaluate the detailed layout based on the handling cost,
inventory requirements (work-in-process in transfer batches and storage locations),
and the safety and efficiency of the handling methods.
6. Write a final report to M Porting reporting:
- the analysis and recommendations from steps 1 to 3.
- the alternative layout and handling systems considered.
- the advantages and disadvantages of your layout.
- the general methodology used to generate your layout.

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Figure 1. Indented bills-of-materials:

Level Part name Quantity Level

Part name Quantity
Standard Cannister 1 0
Discount Cannister 1
Main body 1 1 Main body

Bottom end 1 2 Bottom end

1 Hinged lid 1 1 Flat lid

1
2 Top end 1 1 Fabric cover
1
1 Fabric cover 1 2 Carry strap
1
1 Carry strap 1

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Figure 2. Existing facility layout

Note: Workstation text orientation faces the front of the station, where the operator
stands.

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Table 1. Route sheets for parts and assemblies

Note: Handling methods and transfer batch sizes are based on the current process. They
should be improved wherever possible. The units for the times in the Table 1 are
minutes.