Factory Layout and Material Flows  Case Study - Engineering Assignment Help

Assignment Task:

Task:

Case Study 1 Due: Saturday, March 6th, 11:59PM Consider a a heat treatment facility that is laid out the a flow shop. All new job orders arrive at the Make-up Station, which we call Station 1. In this station, jobs are prepared for heat treatment. This process includes removing the jobs (metal parts to be heat treated) from their packaging, sorting them and putting them in special containers that will go into the furnaces. From here, about 75% of the orders go to the Atmospheric Heat Treatment area, which we call Station 2. The remaining jobs go to the Vacuum Heat Treatment area, which we call Station 4. In stations 2 and 4 the parts undergo the actual heat treatment process, which involves going into one (or several) furnaces at specific temperatures, for specific periods of time. The difference lies in the fact that furnaces in Station 2 operate at atmospheric pressure, while furnaces in Station 4 are sealed and the inside of the furnace creates a vacuum, which avoids corrosion on the surface of the parts during treatment. Of the jobs that leave Station 2, about 25% go to station 3, while 10% of jobs that leave station 4 go to station 3. Station 3 is the shot-blasting department. Shot-blasting is a process sometimes performed after heat treatment, which shoots a fine metal powder at the parts to clean, strengthen and polish their surface. Every job that leaves Station 3, as well as the jobs from Stations 2 and 4 that don't receive shot-blasting go to the Break-down Station, which we call Station 5. In this station, the heat-treated parts are tested, sorted and packaged for shipment. After leaving Station 5, jobs leave the facility. A diagram of the facility is presented in Figure 1. 

Figure 1: Factory Layout and Material Flows 
In stations 1 and 5, each job is handled by one of several available workers. In stations 2, 3 and 4 each job is handled by one of several available machines. Each worker and machine is dedicated to their station and cannot move between stations. We assume that machine loading and unloading is instantaneous and that there is always someone available to do this task (this is a valid assumption as this time is negligible compared to processing time). While furnaces and shot-blasting equipment are completely reliable, workers sometimes need to leave their posts to help with other tasks around the factory, take bathroom breaks, etc. We will model these as failures. Became the times between these activities and their durations are both highly variable we will assume that the time to "failure" and the "repair" time are both exponentially distributed. The service times and failure times at each station are given in the table below. Because the time required to heat-treat a job is quite long, this facility works three 8-hour shifts a day, 7 days a week. Although most jobs arrive during the day on weekdays, the arrival process is very variable, so we will model it as a Poisson process with rate yi (the rate does not change during the day or week). Under the current demand pattern 'Si = 0.95/hour. 
 

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