Question: (a) (i) Re-organising the existing facility is an expensive exercise.

Question

Question:

(a) (i) Re-organising the existing facility is an expensive exercise. Explain how you can delay the factory layout under the following situations:

• The facility is experiencing increased production volume

• Over time the facility has become congested.

(ii) If you have a discrete item manufacturing system, what should be the best approach to factory layout? (Indicate what should be the focus and how you will go about creating the new layout design)

(b) (i) Briefly outline the SMED procedure and explain how cost, quality and flexibility are affected by set –up time reduction.

Explanation / Answer

We will ensure that we have warehouse and go down outside the city limit where we can store all the production for the later stages. We can also ensure that we reduce the production to a extent where we are able to store at MDQ level Here the best way is to shift all the excess products to the company warehouse and from their they can bee send to the locations. The factory layout best approach is to design the layout with the Plant Manager and the project manager who would have a discrete set up where he will have the complete layout diagram inside the plant itself the factory will have all the details of the layout from the factory and project manager. Single minute exchange of dies this reduces the manufacturing cost and Smaller lot sizes,Improve respondness to customer demand,Lower inventory levels,smoother startups. Identify the plot area,identify elements,separate external elements,convert internal elements to external,streamline remaining elements. The cost is reduced as the downtime is reduced by changeover. Quality naturally will improve and not the least we will have the flexibility in deciding about the product.

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