Rezza Prayogi - Master Thesis

UNIVERSITÄT DUISBURG-ESSEN
Facilities Planning
Using Digital Factory
Rezza Prayogi
Master Thesis
This thesis is made as a requirement to complete a Master Study in Production and Logistics
(Mechanical Engineering Department) at Universität Duisburg-Essen (Germany).
Facilities Planning using Digital Factory Master Thesis
ACKNOWLEDGEMENT
I want to say thank you to everyone listed bellow, who gives a big impact in my life
to continue finishing this master thesis.
 To my God (Allah SWT), who always give me a power and a chance to do everything
that’s impossible to do.
 To my dad (Ali Djured) and my mom (Fariha), who always give me a support in
everything I need to finish this master thesis.
 To my uncle (Ir. Ismaun, MM), who always give me support to continue my study.
 To my beloved Rafika Amelia,SE, who always patient in waiting me finishing my
master degree.
 To my Professor in Universität Duisburg-Essen (Prof.Dr.-Ing. Bernd Noche), who
give me a chance and challenge to make this master thesis possible to finish.
 To my all my friends in Universität Duisburg-Essen (Martinus Susilo, Dony Meitia,
Kurnia Saputra, Monfi Subiharto, and a lot more), who always give me a bright day
every day in Germany.
 I also want to thanks to Prof. Dr.-Ing. P.Köhler and Prof. Dr.-Ing. Diethard Bergers
that have been teaching us how to create a world class product using the best software
and system that I have ever learn.
 To Dassault Systemes, who create a great software (Solidworks and Delmia) that’s
make me possible to create this master thesis.
There are more list that should be added here, I’m sorry to not be included here because
of this paper space restriction. I want to thank you to all of you who have helped me, and to
you who read my master thesis
Duisburg, 13 February 2008
Rezza Prayogi
Universität Duisburg-Essen (UDE)

Institute for Product Engineering (IPE)
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ABOUT THE COMPANY
In this Introduction, I give a brief description about Moryl Klebetecnik GmbH (as a
source for my thesis data), SolidWorks, and Delmia QUEST.
1. Moryl Klebetechnik GmbH
H. Moryl GmbH has 15 years experience with the development and production of
Gluing application and Measuring Technology for the most different traders.
Since beginning this year they are to be looked by the union of various specialists and
by the construction of a competent distribution team in the position, the producing industry,
directly and to supply. Therefore they save the detour about the retailers.
They are continuously anxious to adapt developments and constructions to the newest
technological state to contribute thus to the best possible success for customer production. By
the connection compatibility to all market friends to manufacturers they support its customer
to reduce its spare part costs to a minimum.
They support of a producing, innovative and highly competitive partner with a being
convincing complete program for a very good price achievement relation, from certified
service about gluing application and measuring technology, they own control technology and
ultrasonic technology up to servicing and repair of its customer systems.
They produces the following products: Piston pumps systems, gearwheel pumps
systems, barrel glaze devices, coating states, automatic granulate material sponsor, order
control, piston pumps, automatic tubes, pneumatics hand guns, surfaces order heads, order
heads, spray order heads, order modules, nozzles for spray orders, tank filters and sieves,
Inline filters, heating cartridges, Thermostat, magnet valves, glue fittings and screw
connections, ultrasonic systems.
H.Moryl GmbH
Duderstädter Str. 13
D-40595 Düsseldorf
Germany
www.moryl-klebetechnik.com
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2. Solidworks (a part of Dassault Systemes Corporation)
SolidWorks Office Premium is the complete 3D product design solution, providing

your product design team with all the design engineering, data management, and
communications tools that they need in one package. SolidWorks 3D mechanical design
software, perform product design work more quickly and accurately. SolidWorks offers the
most time-saving capabilities of any product design software available.
SolidWorks comes with Design Communication Tools. These tools demonstrate more
effectively how products look and perform with SolidWorks Office Professional design
presentation tools:
 eDrawings Professional-- Generate accurate representations of 2D and 3D models that
anyone can view, mark up, and measure without having to purchase their own mark
up tools.
 SolidWorks Animator-- Create compelling AVI files from SolidWorks parts and
assemblies.
 Photoworks - Create photorealistic images.
 3D Instant Website-- Create and publish live web pages with 3D interactive content.
SolidWorks comes also with CAD Productivity Tools. We can reduce design steps with
SolidWorks Office Professional CAD productivity tools:
 SolidWorks Toolbox-- Automate assembly tasks with a library of standard parts.
 FeatureWorks-- Simplify the reuse of 3D CAD data created in varied file formats.
 SolidWorks Utilities-- Find differences between two versions of the same part quickly
and easily.
 SolidWorks Task Scheduler--Saves time by enabling you to schedule resource
intensive tasks, such as batch printing, running of analyses, and updating of project
files during periods when you will be away from your workstation.
 SolidWorks Design Checker - A timesaving tool for ensuring compliance with your
organization's design standards.
 SolidWorks Routing enables you to quickly and easily design pipe, tube, and
electrical routes in your product designs.
 SolidWorks ScanTo3D enables designers to open scan data in SolidWorks and
convert it into surface and solid models.
SolidWorks comes with Design validation software, which called CosmosWorks.
CosmosWorks specifically tailored for designers and engineers who are not specialists in
design validation, CosmosWorks helps improve product quality by indicating how
SolidWorks models will behave before they are built.
SOLIDWORKS CORP
300 Baker Avenue, Concorde, MA 01742
United States of America
www.SolidWorks.com
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3. Delmia (a part of Dassault Systemes Corp)
DELMIA QUEST provides a single collaborative environment for industrial

engineers, manufacturing engineers, and management to develop and prove out best
manufacturing flow practices throughout the production design process. Improve designs,
reduce risk and cost, and maximize efficiency digitally, before spending money on the actual
facility, to get it right the first time. By using QUEST to experiment with parameters such as
facility layout, resource allocation, kaizen practices, and alternate scheduling scenarios,
integrated product teams can quantify the impact of their decisions on production throughput
and cost
DELMIA QUEST is a powerful simulation development and analysis tool for
validating and visualizing the impact of process flow decisions made for meeting production
requirements. Reduce risk by validating affordability measures, and minimizing problems
and unplanned costs associated with facility startup. QUEST provides a complete solution,
providing the tools necessary for both efficient process flow analysis and effective
presentation of results to customers, managers, and other engineering disciplines.
DELMIA QUEST allows you to quickly build a simulation model to the level of
detail required, adding more detail as necessary to improve accuracy throughout the design
process. Conceptualize your processes by populating the model with intelligent objects and
prebuilt sub-models from your libraries. Once your proposal is accepted, carry the same
model into the design process by integrating it with existing design tools such as 2D/3D
CAD, Microsoft spreadsheet and planning software, and other types of simulation
applications such as ergonomic workplace assessment. Use the QUEST model to document
the lessons learned through the systems integration process, quantifying the impact of design
decisions.
As your facility springs to life in the digital world, the system’s behavior is emulated
with real processing times, speeds, staffing levels, schedules, failure rates, and timing. This
interactive digital environment allows accelerated “what if” analysis to be explored, for
evaluating production scenarios, product mixes, and other alternatives. Results are efficiently
communicated back to the product/process team for incorporating the best solutions. Finally,
as the facility is built, use QUEST to author an Express model of your proprietary processes
and integrate the simulation using QUEST Express™ with your MES, ERP, MRP, PLC, or
scheduling systems for assisting in production floor analysis and systems monitoring. In each
stage, analyzing and presenting QUEST results to decision makers is simple and effective.
DELMIA CORP
900 N. SQUIRREL RD., SUITE 100
AUBURN HILLS, MI 48326
www.delmia.com
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PREFACE
This Master Thesis is based on the ISE Regulation and Master Study Plan for
Mechanical Engineering, that’s must be followed for each student in Universität Duisburg-
Essen.
This Master Thesis is created using my knowledge and combination lecture from
Universität Duisburg-Essen, those lecture are:
 Product Development (Produktentwicklung), Prof. Dr.-Ing. Diethard Bergers

 Computer Aided Calculation and Simulation Methode (Computergestützte
Berechnungs- und Simulationsmethoden), Prof. Dr.-Ing. P.Köhler
 Simulation in Logistics I (Simulation in der Logistik I), Prof. Dr.-Ing. Bernd Noche
 Simulation in Logistics II (Simulation in der Logistik II), Prof. Dr.-Ing. Bernd Noche
 Logistics and Material Flow I (Logistik und Materialfluss I), Prof. Dr.-Ing. Bernd
Noche
 Logistics and Material Flow II (Logistik und Materialfluss II), Prof. Dr.-Ing. Bernd
Noche
 Information System in Logistics (Informationssysteme in der Logistik), Prof. Dr.-Ing.
Bernd Noche
 Facilities Planning and System Engineering I (Anlageplanung und Systemtechnik I),
Dr.rer.nat. Bachtaler
 Facilities Planning and System Engineering II (Anlageplanung und Systemtechnik II),
Dr.rer.nat Bachtaler
 Industrial Engineering, Dr.rer.nat Bachtaler
This Master Thesis theme is to combine a theory and a practice in Facilities Planning
using Digital Factory as a tool. In real world, people is still using manual method to conduct
Facilities Planning, that’s why I want to prove it that using Digital Factory, people can learn,
create, and take a result faster than using manual calculation. Digital Factory can make a
Facilities Planner more understand about their Facilities, but it is only a tool, without a good
knowledge it will become a dumb tool. So the person behind the Digital Factory is still a
must needed component to create a great successful Facility.
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Table of Contents
Acknowledgement ............................................................................................................................... I-2
About the company .............................................................................................................................. I-3
Preface .................................................................................................................................................. I-6
Table of Contents ................................................................................................................................. I-7
Chapter I. Introduction........................................................................................................................ 1-1
I.1. Facilities Planning ....................................................................................................................... 1-1
I.2. Digital Factory ............................................................................................................................ 1-3
Chapter II. Theory ................................................................................................................................ 2-1
II.1. Product Design .......................................................................................................................... 2-1
II.2. Process Design .......................................................................................................................... 2-2
II.3. Schedule Design ........................................................................................................................ 2-2
II.4. Facilities Design ......................................................................................................................... 2-3
II.5. Computer Simulation ................................................................................................................ 2-3
II.6. How to Conduct Successful Facilities Planning ........................................................................ 2-4
II.6.1. Design Product ................................................................................................................... 2-4

II.6.2. Takt Time and Scrap Rates Calculation .............................................................................. 2-6
II.6.2.1. Takt Time ................................................................................................................... 2-6
II.6.2.2. Scrap and Rework ...................................................................................................... 2-7
II.6.3. Process Design ................................................................................................................... 2-8
II.6.3.1. Fabrication ................................................................................................................. 2-8
II.6.3.1.1. Route Sheet .................................................................................................... 2-8
II.6.3.1.2. The Number of Machine Needed ................................................................... 2-9
II.6.3.2. Work Cell Load Chart ............................................................................................... 2-10
II.6.3.3. Assembly and Packout Process Analysis .................................................................. 2-11
II.6.3.3.1. The Assembly Chart ...................................................................................... 2-11

II.6.3.3.2. The Assembly Line Balancing ........................................................................ 2-11
II.6.3.3.3. Packout ......................................................................................................... 2-13
II.6.4. Equipment and Space Used ............................................................................................. 2-14
II.6.4.1. Workstation Design.................................................................................................. 2-14
II.6.4.2. Space Determination ............................................................................................... 2-15
II.6.5. Material Handling Equipment Used................................................................................. 2-16
II.6.5.1. Material Handling Definition ................................................................................... 2-16
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II.6.5.2. Goals of Material Handling ...................................................................................... 2-16

II.6.5.3. The 20 Principles of Material Handling .................................................................... 2-17
II.6.5.4. The Material Handling Problem Solving Procedure ................................................. 2-18
II.6.5.5. Material Handling Equipment .................................................................................. 2-19
II.6.5.5.1. Types of Material Handling Equipment ........................................................ 2-19
II.6.5.5.2. Bulk Material Handling ................................................................................. 2-20
II.6.5.5.3. Fork Lift Truck ............................................................................................... 2-20
II.6.6. Cost Calculation ............................................................................................................... 2-25
II.6.6.1. How Much Will Our Product Cost? .......................................................................... 2-25
II.6.6.2. Material Handling Cost ............................................................................................ 2-26
II.6.6.3. Cost Reduction Formula........................................................................................... 2-26
II.6.7. Tips ................................................................................................................................... 2-27
II.7. How to Build Digital Factory.................................................................................................... 2-27
II.7.1. Getting Started With Delmia Quest ................................................................................. 2-27

II.7.1.1. Introduction ............................................................................................................. 2-27
II.7.1.2. Starting Quest .......................................................................................................... 2-27
II.7.1.3. Configuration Files ................................................................................................... 2-30
II.7.1.4. The User Interface ................................................................................................... 2-31
II.7.1.5. Pull Down Menu (Context Button) .......................................................................... 2-32
II.7.1.6. World Control Button .............................................................................................. 2-33
II.7.1.7. Using the Mouse ...................................................................................................... 2-37
II.7.2. Step by Step to Build Delmia Simulation ......................................................................... 2-37
Chapter III. Project and Calculation .................................................................................................... 3-1
III.1. Introduction ............................................................................................................................. 3-1
III.2. Design of Gas Grill .................................................................................................................... 3-1
III.3. Takt Time and Scrap Rates Calculation .................................................................................... 3-4
III.4. Process Design ......................................................................................................................... 3-7
III.4.1. Cycle Time and Fraction Equipment ................................................................................. 3-7
III.4.2. Assembly Chart and Packaging Line................................................................................ 3-16
III.4.3. Flow Analysis Technique ................................................................................................. 3-22
III.4.4. Activity Relationship Analysis ......................................................................................... 3-40
III.5. Equipment and Space Used ................................................................................................... 3-50
III.6. Material Handling Equipment Used ....................................................................................... 3-57
III.7. Cost Calculation...................................................................................................................... 3-61
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Chapter IV. Building Digital Factory .................................................................................................... 4-1

IV.1. Delmia Quest ........................................................................................................................... 4-1
IV.2. Experiment............................................................................................................................... 4-1
IV.2.1. Single Machine.................................................................................................................. 4-1
IV.2.2. Three Assembly Machine ................................................................................................. 4-2
IV.2.3. Conveyor System .............................................................................................................. 4-4
IV.2.4. Power and Free System .................................................................................................... 4-5
IV.2.5. Labor, Shift, and Downtime .............................................................................................. 4-7
IV.2.6. Labor I ............................................................................................................................... 4-9
IV.2.7. Labor II ............................................................................................................................ 4-10
IV.2.8. Labor III ........................................................................................................................... 4-11
IV.2.9. Pallet ............................................................................................................................... 4-13
IV.3. Gas Grill Manufacturing Simulation....................................................................................... 4-14
IV.3.1. Axle Production .............................................................................................................. 4-14
IV.3.2. Tank Holder Production .................................................................................................. 4-15
IV.3.3. Bottom Support Production ........................................................................................... 4-20
IV.3.4. Top Support Production ................................................................................................. 4-24
IV.3.5. Control Panel Production ............................................................................................... 4-29
IV.3.6. Tube Plugs Production .................................................................................................... 4-33
IV.3.7. Legs Extensions Production ............................................................................................ 4-36
IV.3.8. Knob Production ............................................................................................................. 4-39
IV.3.9. Legs Production .............................................................................................................. 4-42
IV.3.10. Wood Slats Production ................................................................................................. 4-46
Chapter V. Conclusion ......................................................................................................................... 5-1
V.1. Advantages ............................................................................................................................... 5-1
V.2. Disadvantages ........................................................................................................................... 5-1
LYBRARY .............................................................................................................................................. L-1
APPENDIX ........................................................................................................................................... A-1
A.1. Appendix I – Delmia Quest Modeling Terms ............................................................................A-2
A.2. Appendix II – CAD Modeling Terms ........................................................................................A-16
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CHAPTER I
INTRODUCTION
I.1. Facilities Planning

Facilities planning determine how an activity’s tangible fixed assets best
support achieving the activity’s objective. For a manufacturing firm, facilities
planning involve the determination of how the manufacturing facility best supports
production.
It is important to recognize that contemporary facilities planning considers the
facility as a dynamic entity and that a key requirement to facilities plan is its
adaptability, that is, that facility’s ability to become suitable for new use. In this
regard as a facilities planner, the notion of continuous improvement must be an
integral element of the facilities planning cycle. The continuous improvement
facilities planning cycle shown in Figure I.1, details this concept.
Whether we are involved in planning a new facility or planning to update an
existing facility, the subject matter should be of considerable interest and benefit. As
depicted in Figure I.2, it is convenient to divide a facility into its location and its
design components.
The location of the facility refers to its placement with respect to customer,
suppliers, and other facilities with which it interfaces. Also, the location includes its
placement and orientation on a specific plot of land.
The design components of a facility consist of the facility systems, the layout,
and the handling system. The facility systems consist of the structural systems, the
atmospheric systems, the enclosure systems, the lighting/electrical/communication
systems, the life safety systems, and furnishings within the building envelope; and the
handling system consists of the mechanisms needed to satisfy the required facility
interactions.
The facility systems for a manufacturing facility may include the envelope
(structure and enclosure elements), power, light, gas, heat, ventilation, air
conditioning, water, and sewage needs. The layout consists of the production areas,
production-related or support areas, and personnel areas within the building. The
handling system consists of the materials, personnel, information, and equipment
handling systems required to support production.
Determining how the location of a facility supports meeting the facility’s
objective is referred to as facilities location. The determination of how the design
components of a facility support achieving the facility’s objectives is referred to as
facilities design. Therefore, facilities planning may be subdivided into the subject of
facilities location and facilities design. Facilities location addresses the macro issues
whereas facilities design looks at the micro elements.
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Specify/update primary and

related activities to
accomplish objectives
Determine space requirement

for all activities
What’s
the feasibility Determine
Maintain and of incorporating the No facility
continuously new operation or
improve location
facility on
existing
site?
Yes
Develop alternative plans and

evaluate
Select facilities plan
Implement plan
Figure I.1 Continuous improvement facilities planning cycle1
Facilities
location
Facilities
planning
Facilities systems design
Facilities Layout design

design
Handling systems design
Figure I.1 Facilities planning hierarchy1
1
Facilities Planning, 2nd ed. Tompkins, White, Bozer, Frazelle, Tanchoco, Trevino. McGraw-Hill
1996.
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I.2. Digital Factory
The digital factory defined (in Generic term) as a comprehensive network of

digital models and methods among other things simulation and 3D-Visualization.
Their purpose is the holistic planning, realization, controlling and current improving
of all substantial factory processes and - resources in connection with the product
On the one hand by the digital factory an image of the material factory is
understood, in order the processes running off therein to visualize, simulates and thus
better to understand to be able. On the other hand the digital factory than the whole of
all coworkers, software tools and processes, who are necessary for the production of
virtual and material production, is defined.
Further must be separated between the tools and methods of the digital factory
and the vision of virtual production and virtual logistics.
Virtual production designates as constant, experimentable planning, evaluation
and control of production processes and - lay close with the help of digital models.
The term of virtual logistics describes the software-supported planning of logistic
processes and structures.
Effective range of the digital factory is the production planning phase within
the product life cycle. During this phase the main operating cost blocks are specified.
Their purpose is the holistic planning, realization, controlling and current
improving of all substantial factory processes and - resources in connection with the
product (e.g. Motor vehicle, airplane).
With the digital factory the field of activity between the production
development and the production control is closed. While for production development
and production control different methods and systems on the free market are
acquisition, production planning is only meagerly supported.
Principal activities during the product life cycle for the elucidation of the
emphasis range of the digital factory can bee seen in Figure 1.1 below.
Figure I.1 Focus of the digital factory is production planning2

2
Reinhard, G.; Grundwald, S.; Rick, F.: Virtuelle Produktion – Virtuelle Produkte im Rechner
produzieren. In: VDI-Z, 141, (1999) 12, S. 26.
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The digital factory does not only consist of software. The digital factory must
be seen in the total context of the enterprise and can into four levels of the digital
factory be arranged in such a way:
 Database
 Integration platform
 Tools
 Organization and planning workflow
A goal of the digital factory is it, proven methods, to standardize processes

and operational funds in such a way that they can be used with another product or
with the successor than planning components again. For this usually a revision of the
existing processes and the organization is necessary.
During the process reorganization should on the four directions of attack of the
digital factory.
 common data base for the reduction of redundant data
 Standardization of processes, resources as well as operational funds
 consistent clarification of task, authority and responsibility over the process
chain into a trade-spreading integrating process as well as
 Possibilities for automation are respected.
Tasks of the digital factory are among other things:

 Assumption of the product planning data,
 Process time planning,
 Planning of the production processes,
 Planning of the operational funds (construction proposal, definition number),
employment factor planning,
 Layout planning of the work and the jobs,
 Cost evaluation as well as
 Security of the results of planning
 Delivery of the planning data to the enterprise.
Increase in value of the digital factory is not only that costs are lowered with
the purchase by parts and plants, but offers also substantial advantages regarding
maintenance, flexibility and reliability. Routine activities of planning are transferred
to the software.
All process-taken part of planning settles its tasks at the computer and by
Workflows are interlaced. Fixed times the progress in the planning process is made
measurable. That secures the availability of the desired data at the correct time, in
correct detailing and in the correct context.
All relevant planning data (product, process, resources) are only once seized
by the ranges involved and administered by a data base. They are for each planner, in
the future also for suppliers, outfitters and suppliers, always in the current form
available. A nuclear goal is it to be able to use the data with new models very early to
meet about in order for cost estimation.
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Figure I.2 Area of digital factory3
However does not have itself the digital factory was located today (in the
middle of 2007) surface covering in the producing industry as planning system
interspersed. So far only large-scale enterprises trust in the new technology. Reasons
for this are because of to high costs and the unclear use. Further it lacks in the
operational daily business within many ranges the necessary user acceptance.
3
Reinhard, G.; Grundwald, S.; Rick, F.: Virtuelle Produktion – Virtuelle Produkte im Rechner
produzieren. In: VDI-Z, 141, (1999) 12, S. 26
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Facilities Planning Using Digital Factory Master Thesis
CHAPTER II
THEORY
II.1. Product Design

Product design involves both the determination of which products are to be
produced and the detailed design of individual products. Decisions regarding the
products to be produced are generally made by top management based on input from
marketing, manufacturing, and finance concerning projected economic performance.
In other instances, the lead times to plan and build facilities, in the face of a dynamic
product environment, might create a situation in which it is not possible to accurately
specify the products to be produced in a given facility.
Figure II.1 Exploded assembly drawing
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If it is decided that the facility is to be designed to accommodate changes in

occupants and mission, then a highly flexible design is required and very general space
will be planned. On the other hand, if it is determined that the products to be produced
can be stated with a high degree of confidence, then the facility can be designed to
optimize the production of those particular products.
The design of the product is influenced by aesthetics, function, materials, and
manufacturing considerations. Marketing, purchasing, industrial engineering,
manufacturing engineering, product engineering, and quality control, among others,
will influence the design of the product. In the final analysis, the product must meet
the needs of the customer.
The drawing can be prepared and analyzed with computer aided design (CAD)
systems. CAD is the creation and manipulation of design prototypes on a computer to
assist the design process of the product. A CAD system consists of a collection of
many application modules under a common database and graphics editor. The
blending of computers and the human ability to make decisions enable us to use CAD
systems in design, analysis, and manufacturing.
During the facilities design process, the computer’s graphics capability and
computing power allow the planner to visualize and test ideas in a flexible manner.
The CAD system also can be used for area measurement, building and interior design,
layout of furniture and equipment, relationship diagramming, generation of block and
detailed layouts, and interference checks for process oriented plants.
II.2. Process Design

The process designer or process planner is responsible for determining how the
product is to be produced. As a part of that determination, the process planner
addresses who should do the processing; namely, should be a particular product,
subassembly, or part be produced in-house or subcontracted to an outside supplier or
contractor? The ―make or buy‖ decision is part of the process planning function.
In addition to determining whether a part will be purchased or produced, the
process designer must determine how the part will be produced, which equipment will
be used, and how long it will take to perform the operation. The final process design is
quite dependent on input from both the product and schedule designs. This will
explained later in sub-chapter II.6.
II.3. Schedule Design

Schedule design decisions provide answers to questions involving how much
to produce and when to produce. Production quantity decisions are referred to as lo
size decisions; determining when to produce is referred to as production scheduling. In
addition to how much and when, it is important to know how long production will
continue; such a determination is obtained from market forecasts.
Schedule design decisions impact machine selection, number of machines,
number of shifts, number of employees, space requirements, storage equipment,
material handling equipment, personnel requirements, storage policies, unit load
design, building size, and so on. Consequently, schedule planners need to interface
continuously with marketing and sales personnel and with the largest customers to
provide the best information possible to facilities design planners.
To plan a facility, information is needed concerning production volumes,
trends, and the predictability of future demands for the products to be produced. The
less specify provided regarding product, process, and schedule design, the more
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general purpose will be the facility plan. The more specific the inputs from product,
process, and schedule design, the greater the likelihood of optimizing the facility and
meeting the needs of manufacturing.
II.4. Facilities Design

Once the product, process, and schedule design decisions have been made, the
facilities planner needs to organize the information and generate and evaluate layout,
handling, storage, and unit load design alternatives. Some tools frequently used by
quality practitioners (e.g., Pareto chart) can be very useful in facilities planning efforts.
Product
design
Facilities
design
Process
design Schedule
design
Figure II.2 Relationship between product, process, and schedule design and
facilities Planning
II.5. Computer Simulation
Simulation is defined as an experimental technique, usually performed on a

computer, to analyze the behavior of any real-world system. Simulation involves the
modeling processor or a system where the model produces the response of the actual
system to events that occur in the system over a given period of time.
Simulation can be used to predict the behavior of a complex manufacturing or
service system by actually tracking the movements and the interaction of the system
components. The simulation software generates reports and detailed statistics
describing the behavior of the system under study. Based on these reports, the physical
layouts, equipment selection, operating procedures, resource allocation and utilization,
inventory policies, and other important system characteristics can be evaluated.
Simulation modeling has two important characteristics that set simulation apart
from other forms of analysis. Simulation modeling is dynamic, in that behavior of the
model is tracked over simulated time. A simple what-if analysis is static in nature. The
state of a static model doesn’t change as a function of time. If we were simulate the
roll of a die, then the output of the model would not affected by time. However, if we
were to simulate the utilization or breakdown of a machine, or the accumulation of
work-in-process inventory at a workstation, then these phenomena would not be static
in nature. Equipment utilization or breakdown, material handling and transportation
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systems behavior, and interaction among various activities in a manufacturing cell, for
instance, are dynamic in nature and the output of such models is a function of time.
Secondly, simulation is a stochastic model rather than a deterministic one. For
example; if the mean time to failure (MTTF) for a piece of equipment is 1000 hours, it
does not mean that the equipment will necessarily fail once every 1000 hours. Such an
expectation would create a deterministic model. In the real world, the breakdown
follows a particular statistical distribution, that is, exponential , Weibull, and so on. A
random simulation model allows for these real-life breakdowns or other random
occurrences.
Figure II.3 Computer simulations in manufacturing facilities design
Computer simulation and modeling are rapidly becoming important in the

manufacturing and service segment of industry. Although computer simulation and
modeling are not new to solving complicated mathematical problems or to providing
insights into sophisticated statistical distribution, the power of the new generation
software has dramatically increased the application of computer modeling as a
problem-solving tool in the facilities design arena.
II.6. How to Conduct Successful Facilities Planning

To conduct successful facilities planning we need to make a lot of manual
calculation and using excel. Data need to be collected before we make a trial and error
calculation.
In this sub-chapter I will presented step by step how to do this, and a theory
behind each step.
II.6.1. Design Product

Blueprints, bill of materials, assembly drawings, and model shop samples
inform the facilities designer of the prime mission – a detailed description of what
needs to be accomplished. The product design step is the source of this valuable
information. The first question anyone would ask when assigning a new facility design
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project is, ―What are we going to make?‖ The output of this product design step tells
us exactly what we are going to manufacture.
Blueprints, sketches, pictures, CAD (Computer-Aided Design) drawings, and
model shop samples all communicates the idea of what we want to build. There will be
drawings of each individual part of the product as in Figure II.4. These drawings will
tell us the size, shape, material, tolerances, and finish. Assembly drawings (see Figure
II.1) show many parts (if not all parts) and how they fit together. An exploded drawing
is an especially useful drawing for the facilities designer because it helps us to
visualize how the parts fit together. Centerlines are used to separate parts and the parts
are aligned to show the assembly relationship. These give the facility designer clues to
the sequence of assembly.
Figure II.4 Sample blueprint for production purpose
When the facility designer is working on the assembly line layout, the
exploded drawing will be the guide. The facility design cannot get started without
blueprints or sketches.
Either a parts list or a bill of materials will be provided to the facility
designer by the product engineering department with each new product. The part list
and bill of materials are the same thing and list all the parts that make up a finished
product. This list includes part numbers, part names, the quantity of each part, what
parts make up subassemblies, and may include material specifications, parts and raw
material unit costs, and make or buy decisions. The make or buy decisions are a total
management decision not just the product engineering department, but the parts list is
a good place to indicate that decision.
Table II.1 Indented Bill of Materials

Level Part No. Part Name Drwg. No. Qty/Unit Make/Buy
0 STG1 Packaged grill DWG1 1 M
1 PP1 Bottom grill casting PDWG1 1 B
1 PP2 Grease can wire PDWG2 1 B
1 PP3 Top grill casting PDWG3 1 B
1 PP4 Wood handle PDWG4 1 B
1 STG4 Legs DWG4 4 M
2 STG8 Top support DWG8 2 M
The intended bill of material is also an important aid in the design of the
facility and configuration of the work cells and assembly lines (see Table II.1). An
indented bill of material provides the same basic information as the parts list.
However, the indented bill of material presents the hierarchical structure of the product
by identifying each assembly, subassembly, and the required or subordinate parts of
each assembly or subassembly. The highest level of the product, or the finished
assembly, appears on the top of the list and is given level number zero (0). Under this
are listed the major assemblies and each is assigned as level one (1). The period before
the numeral (1) serves to indent the major subassemblies from the main assembly.
Under each subassembly, the required components which comprise that subassembly
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are listed and numbered level two (2). In turn, under each component, subordinate
parts are listed and each is numbered as level three (3). If a given level itself is
comprised of multiple parts, those parts would be listed following the given level three
part and would be numbered level four (4), and ad infinitum. The purpose of the
periods before each level number is to offset or indent (hence indented bill of material)
each level in order to enhance readability.
The indented bill of material not only provides data regarding the composition
of the final assembly, but it also provides valuable insight into the flow of parts and
components in the final assembly.
Companies themselves do not fabricate every part of their product. The parts
that are purchased complete are called buyouts and can be fabricated cheaper by
someone else. Some companies purchase every part complete from outside. These
companies are called assembly plants. The part that we ―make‖ are basic requirements
for the fabrication end of our facility.
The product engineering department can be very helpful to the plant facility
designer. It can point out special manufacturing problems, critical relationships,
dimensions, and function. The product designer and the facility designer need to work
closely together. The up-front communication and cooperation between the product
designer and facility planner is one aspect of concurrent engineering.
II.6.2. Takt Time and Scrap Rates Calculation
II.6.2.1. Takt Time

Takt time can be defined as the maximum time allowed to produce a product in
order to meet demand. It is derived from the German word taktzeit which translates to
clock cycle. There is a logic therefore to setting the pace of production flow to this takt
time. Product flow is expected to fall within a pace that is less than or equal to the takt
time. In a lean manufacturing environment, the pace time is set equal to the takt time.
Takt Time is defined as:
𝑇𝑎
𝑇=
𝑇𝑑
Where:
Ta = Net Available Time to Work eg. [minutes of work / day]
Td = Total demand (Customer Demand) eg. [units produced / day]
T = TAKT Time eg. [minutes of work / unit produced]
Net available time is the amount of time available for work to be done. This
excludes break times and any expected stoppage time (for example scheduled
maintenance, Team Briefings etc).
As an example, if you have a total of 8 hours in a shift (gross time) less 30
minutes lunch, 30 minutes for breaks (2 x 15 mins), 10 minutes for a Team Brief and
10 minutes for basic Operator Maintenance checks, then; Net Available Time to Work
= (8 hours x 60 minutes) - 30 - 30 - 10 - 10 = 400 minutes.
If Customer Demand was, say, 400 units a day and you were running one shift,
then your line would be required to spend a maximum of one minute to make a part in
order to be able to keep up with Customer Demand.
In reality, people can never maintain 100% efficiency and there may also be
stoppages for other reasons, so allowances will need to be made for these instances
and thus you will set up your line to run at a proportionally faster rate to account for
this.
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Takt time has direct implications concerning the allowable time for completing
individual steps in a production process. This is the case for both steps that modify
(form, assemble, finish…) the product and also the steps that observe and control (test,
measure, adjust…) the process. Similarly steps which require a part or assembly of the
product to have been put into an accurately fixtured position must be completed in less
than the total takt time so that time is allowed for loading and unloading or positioning
the part in addition to the time for actually performing the production step. The
quicker that a measurement or test step can be completed, the less constraint is placed
upon product motion between steps. For example, a measurement process that captures
the entire information about a part at once will permit shorter total takt time and a
higher pace of production flow. Elimination of the need to measure reduces this step
best (See SMED).
An implication of using takt time can be that work packages get reorganised. If
worker one performs actions A1 through A5 and worker two performs actions A6
through A8 then a reduction in takt time may mean that there are now three work
packages required to fit the new shorter/faster pace. They might be package 1 (A1 to
A4), package 2 (A5 to A6) and package 3 (A7 to A8). So now we will have three
people working to do the work that used to be achieved by two. This subdivision of
workpackages rather than parallel working on unchanged packages of actions is a new
idea to many. This way of working requires:
 a very flexible workforce, that is willing to accept changes in their routines
and workplace
 requires a multi-skilled workforce, since now people may be asked to 'pick-up'
actions currently performed by others
 flexible workcells, since what is being done by two people today may need to
accommodate three people tomorrow
 increases hand-offs, so these must have no significant overhead
 keeps the workflow simple and easy to manage, so whether the process will
deliver is clear to all
 has been observed to speed up individual steps in production, because the new
context of each action encourages innovation.
It will be obvious that this kind of capacity replanning is not something that
will be desirable every week. It is therefore important that the varying part of Takt
time, the customer demand, should have been leveled before this kind of work
replanning is undertaken. That leveling is looked at elsewhere and that therefore this
style of capacity modification should be undertaken to meet long term customer
demand changes and not weekly forecasts.
II.6.2.2. Scrap and Rework

Although quite undesirable, manufacturing operations do produces scrap or
unusable parts. Furthermore, often here is a need to redo an operation simply because
the part was not produce within the desired specifications the first time. This is called
rework. Scrap and rework result in an inefficient and wasteful use of the facilities
resources. Every effort should be made to eliminate such waste. However, as long as
we have to deal with scrap and rework, we cannot ignore their demand on our
production time.
Quality and production department have historical data that can indicate the
level of rework and scrap for each operation. In determining the plant rate, or takt
time, we must include scrap and rework rates into our calculations. Indeed, it is also
prudent to add into these calculations the need for spare or replacement parts.
The general formula is stated as:
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𝑜𝑢𝑡𝑝𝑢𝑡
𝐼=
1 − %𝑠𝑐𝑟𝑎𝑝1 1 − %𝑠𝑐𝑟𝑎𝑝2 1 − %𝑠𝑐𝑟𝑎𝑝3 … (1 − %𝑠𝑐𝑟𝑎𝑝 𝑛)
To illustrate, if we need 2000 part/day with 3 operations, each operation has its
own scrap rates. Operation 1 is 30%, operation 2 is 25%, operation 3 is 5%. We
calculate how much we need this part is:
2000
𝐼= = 2,125 𝑢𝑛𝑖𝑡𝑠
1 − 0,03 1 − 0,025 1 − 0,005
II.6.3. Process Design

The process designer determines how the product and all its components will
be made. The information provided by the process designer would include the
following:
1. The sequence of operation to manufacturing every part in our product (they
―make‖ parts only because the ―buy‖ parts will not be our company’s problem)
2. The needed machinery, equipment, tools, fixtures, and so on
3. The sequence of operations in assembly and Packout
4. The time standard for each element of work
5. The determination of the conveyor speeds for cells, assembly and Packout
lines, and paint or other finishing systems
6. The balance of the work loads of assembly and Packout lines
7. Load work cells
8. The development of a workstation drawing for each operation using all the
principle of motion economy and ergonomics.
Process design can be divided into two broad categories, fabrication and
assembly. Fabrication process design is initially planned on a route sheet. Assembly
and Packout process design uses the techniques charts and assembly line balancing.
II.6.3.1. Fabrication
The sequence of steps required to produce (manufacture) a single part is
referred to as the routing. We route the part from the first machine to the second
machine and so on until we have a finished part that will be united with other parts.
The form used to describe this routing is called the route sheet.
II.6.3.1.1. Route Sheet

A route sheet (see Table II.2) is required for each individual fabricated part of
our product (make part). If our finished product that is to be manufactured has 30
different parts and we buy 10 from outside the company (buyouts), and make 20 parts
ourselves, we will need 20 route sheets. The route sheet lists the operations required to
make that part in proper sequence. The route sheet gets its name from the way it is
used. A copy of the route sheet would be issued by the production and inventory
control department showing the order quantity. The route sheet would accompany the
material from operation to operation telling the operators what to do. The route sheet
will tell the plant personnel about the part number, part name, quantity to produce,
operation number, operation description, machine number, machine name, tooling
needed, and time standard.
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Table II.2. Route Sheet for one part

Part No. Part Name Drawing
No.
STG13 Knob DWG13
Operation Operation Machine Machine Cycle Fraction Pieces/ Hours/ Hours/

No. Description No. Time Equipment Hours pieces 1000
75 Molding NISSEI NS60 0,125 0,194 480 0,00208 2,083
NS60
65 Trimming Ergonomic ERGCT 0,060 0,093 1000 0,001 1
Cutters
The route sheet ends with the last operation prior to being assembled with other
parts. For example, if three parts are going to be welded together, the individual parts
lose their identity once joined with other parts, so that the route sheet would end
before welding. If an individual part goes through a clean, paint, and bake operation
before being assembled, then the clean, paint, and bake procedure would be included
on the route sheet.
The sequence of operations as shown on the route sheet affects the proper
layout of the equipment on the production floor. We want the material to flow
smoothly through the plant from the raw material stores to the first operation, to the
second operation whose machine is right next to the first machine. This will ensure
that the part travels as short a distance as possible. Process-oriented layouts are where
you collect all like machines together and bring all parts to them, where product-
oriented layouts place machine where they are needed to eliminate excessive moving.
Skipping over machines and backtracking will result from process layouts and must be
discouraged because it adds costs without adding to the value. When many parts are
fabricated in one group of machines (called a process layout), jumping around may be
necessary, but we want to minimize this jumping, skipping and backtracking. There
are two ways to change the sequence in order to make the flow through the plant
smoother:
1. Change the route sheet (paper change) if possible so that the sequence of
operation agrees with the other parts or the plant layout.
2. Change the physical layout of the machines so that the machines are in the
correct sequence.
Changing the paperwork is our first choice because it is the cheapest way.
Time standards are an important part of the route sheets. Time standards are
used to determine how many machines are needed in our layout. They are another
piece of information that may come from another group within the manufacturing
engineering department, but in many companies, time standards are developed by the
manufacturing facilities designer.
II.6.3.1.2. The Number of Machines Needed
How many machines should we buy? This question can only be answered when we
know:
1. How many finished units are needed per day?
2. Which machine runs what parts?
3. What is the time standard for each operation?
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How many finished units are needed per day? The marketing department tells
us how many products to produce (manufacture) per day. Which machine runs what
parts? The route sheets produced in the previous section will tell us which machines
are needed to produce each part. What is the time standard for each operation for each
part? The time standard for every operation on every part is in both pieces per hour
and decimal minute. We need the decimal minute time standards to compare with the
Takt Time.
Once we know the plant rate (takt time), the machines to be used, and the time
standards, we divide the time standard (decimal minute) by the plant rate. The
resultant number of machines should be in two decimal places (i.e., 0,46 machine).
Once all the machine requirements for each operation have been calculated, we total
similar machine requirements and round up recommending the purchase of enough
machines. Always round up on the total machines, otherwise a bottleneck will be
created and we will not produce exact number of product per day, unless our plant
work overtime. If due to economic considerations, rounding up cannot be justified,
overtime may need to be planned for these operations in order to meet production
requirements and to alleviate bottlenecks. If investment can be justified, and the
production volume is warranted, then rounding up is recommended.
This information on the number of machines required will be used later to
determine the number of square feet of floor space needed in our fabrication
department.
II.6.3.2. Work Cell Load Chart

The work cell load chart is different from the previous techniques in that it
does not have to be for a complete part or product, but it could be for only a few
operations. We could end up with a complete part; however, that it not the goal of a
work cell.
A work cell is a collection of equipment required to make a single part or a
family of parts with similar characteristics. This equipment is placed in a circle around
an operator or operators (see Figure II.5). The operator (most often a single operator)
then takes a part from the in-basket and moves that part around the circle of
equipment. Equipment is usually automatic machines that only need to be loaded,
activated, and then unloaded. Once the machine is loaded and activated, the operator
moves the just completed part from the first machine to the second, where the operator
removes the previous part and loads the next part. This process continues around the
cell: taking parts out of one machine, putting new parts back into this machine, then
activating that machine until arriving at the last machine, where the part is removed,
inspected, and placed in the finished parts basket. Work cell are being developed at a
very fast rate because they
1. Significantly reduce setup time
2. Eliminate all storage between operations
3. Eliminate most of the moving time between operations
4. Eliminate delays spent waiting for the next machine
5. Reduce cost
6. Reduce inventory (work-in-process reductions)
7. Reduce manufacturing in process time
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Drill# 1 Drill# 2
4 holes 4 holes
4 6
In 2
C‖ bore
8 8 holes
Out 14
12 10
0
Tap Ream
8 holes 8 holes
Figure II.5. Work cell Layout
These are the goals of lean manufacturing and a good description of

eliminating ―muda‖ or waste. The work cell concept considers operator (utilization) to
be more important than machine utilization.
Work cell load charts are a special operations chart used for multi-machine
situations. Work cell load charts will visually show the operator time, machine time,
and walking time required to run a work cell to produce one part per cycle using many
machines. The result of the work cell load chart will show us the total cycle time,
proper utilization, and machine utilization. Because they are visual, work cell load
charts help people to see problems and to make improvement on the operation by
properly loading the operator, operators, and/or machines. A work cell will appear on
the route sheet as one operation.
II.6.3.3. Assembly and Packout Process Analysis

Once all parts are produced by the fabrication departments or received from the
suppliers and available for assembly, new analytical tools are needed. Subassembly,
welding, painting final assembly, and Packout are all function included in this area of
the plant.
II.6.3.3.1. The Assembly Chart

The Assembly Chart shows the sequence of operations in putting the product
together. Using the exploded drawing and the part list, the layout designer will
diagram the assembly process. The sequence of assembly may have several
alternatives. Time standards are required to decide which sequence is best. This
process is known as assembly line balancing.
II.6.3.3.2. Assembly Line Balancing

The purpose of the assembly line balancing technique is:
1. To equalize the work load among the assemblers
2. To identify the bottleneck operation
3. To establish the speed of the assembly line
4. To determine the number of workstations
5. To determine the labor cost of assembly and Packout
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6. To establish the percentage workload of each operator

7. To assist in plant layout
8. To reduce production cost
The assembly line balancing technique builds on the assembly chart (Figure
II.6) time standards and the plant rate (takt time). The objective of assembly line
balancing is to give each operator as close to the same amount of work as possible.
This can only be accomplished by breaking the taks into the basic motions required to
do every single piece of work and reassembling the tasks into jobs of near equal time
value. The workstation or stations with the largest time requirement is designated as
the 100% station and limits the output of the assembly line. If industrial engineers
want to improve the assembly line (reduce costs), they would concentrate on the 100%
station. Reduce the 100% station in our example below by 1% and save the equivalent
of 0,25 people, a multiplying factor of 25 to 1.
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Grill Legs (2)
Spot Weld
SA1
Side Support (1) (×2)
Paint
P1 Paint
Control Panel (1)

SA2
Bottom Support (2)
SA3
Paint
P2 Paint
Paint
P3 Paint
Tank Holder (1)

SA4
Wood Slats (4)

SA5
Casting
Ignitor
Purchase Parts
Grates SA6
Gas Valving
Burner
Feet & Knob

Fasteners
Bagging
Instructions SA7
Poly Bag
Cardboard Box
Staples
P.O
Cardboard Packing
Figure II.6. Assembly Chart
II.6.3.3.3. Packout
Packout work is considered to be the same as assembly work as far as
assembly line balancing is concerned. Many other jobs may be performed on or near
the assembly line, but they are considered subassemblies and are not directly balanced
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to the line because subassemblies can be stockpiled. Their time standards stand on
their own merit.
II.6.4. Equipment and Space Used
II.6.4.1. Workstation Design

Choosing equipment comes from process design, but the space needed and
workstation design must be calculated separately using ergonomics. The result of
ergonomics and workstation design is a workstation layout, and the workstation layout
determines the space requirements. The manufacturing department’s total space
requirements are just a total of individual space requirements plus a little extra factor.
Ergonomics is the science of preventing muscular/skeletal injuries in the
workplace. It is the study of workplace design and the integration of workers with their
environment. Ergonomic considerations include employee size, strength, reach, vision,
cardiovascular capacities, cognition, survivability, and cumulative muscular/skeletal
injuries. The golden rule may be stated as follows: Design the work or the workstation
so that the task fits into the person rather than attempts to force the human body or
psyche to fit into the job.
The resulting workstation design is a drawing, normally a top view, of the
workstation, including the equipment, materials, and operator space. Designing
workstations has been an activity performed by industrial and manufacturing engineers
for nearly a century. During this period of time, the profession has developed a list of
principles of ergonomics and motion economy that all new engineers should learn and
apply. When these principles are applied to the design of a workstation, the most
efficient and safe motion patterns will result.
―Where to start?‖ is the first question most often asked by new workstation
designer. The answer is very simple – start anywhere! No matter where you start in
designing a workstation, another idea will come along making that starting point
obsolete. Where to start depends a great deal on what is to be accomplished at that
workstation. The cheapest way to get into production is usually the best rule for the
starting point. The cheapest way means just that – the simplest machines, equipment,
and workstation. Savings must justify any improvement on this most economical
method. Therefore, the designer is free to start anywhere, then improve on the first
method.
The following information must be included in any workstation design:
1. Worktable, machines, and facilities

2. Incoming materials (materials, packaging and quantity must be considered)
3. Outgoing material (finished product)
4. Operator space and access to equipment
5. Location of waste and rejects
6. Fixture and tools
7. Scale of drawing (see Figure II.7)
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Figure II.7. Workstation layout for Bending Machine
A three-dimensional drawing would show an even greater amount of

information. Any talented designer could attempt a three-dimensional design.
II.6.4.2. Space Determination

The space determination procedure for most production departments start with
the workstation design. From each workstation layout, we measure the length and
width to determine the square foot of each workstation.
Multiplying the total square feet by 150% allows extra space (this could be
200% if management wants to provide a spacious layout, or a larger contingency
allowance) for the aisle, work in process, and a small amount of miscellaneous extra
room. It does not include restrooms, lunchrooms, first aid, tool rooms, maintenance,
offices, stores, warehouse, shipping, or receiving. The extra 50 to 100% space added
to the equipment space requirement will be used mostly for aisles. Aisles can be very
space consuming.
Table II.2 Example of Equipment Space Requirement

Machine Name Operation Machine code Space Required
JUTEC 850 Bender JTC850 106 ft2 = 9,85 m2
DrillPress Drill 8062 TRADESMAN 34 ft2 = 3,16 m2
Lincoln Resitance Welder LR560 67 ft2 = 6,23 m2
MINTER 300 Stamp MNS300 476 ft2 = 44,22 m2
Big 800 Wood/Steel Saw B800 152 ft2 = 14,12 m2
RYOBI Sander RBS 31 ft2 = 2,88 m2
SHARP Poly Bag J69 64 ft2 = 5,95 m2
Ingersoll Rand Paint Booth IR800 440 ft2 = 40,88 m2
NISSEI Injection Mold NS60 73 ft2 = 6,78 m 2
Small space consuming items such as an air compressor or drinking fountain

may be included in this 50% extra area, but large area requirements must be designed
and planned.
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II.6.5. Material Handling Equipment Used
II.6.5.1. Material Handling Definition

Material Handling is the function of moving the right material to the right
place, at the right time, in the right amount, in sequence, and in the right position or
condition to minimize production costs.
Material control systems are an integral part of modern material handling
systems. Part numbering systems, location systems, inventory control systems,
standardization, lot size, order quantities, safety stocks, labeling, automatic
identification techniques (bar coding) are only some of the systems required to keep
industrial plants material moving.
Material handling can be broadly defined as all movement of materials in a
manufacturing environment. The American Society for Mechanical Engineers
(ASME) defines material handling as the art and science involving the moving,
packaging, and storing of substances in any form. Material handling may be thought of
as having five distinct dimensions: movement, quantity, time, space and control.
Movement involves the actual transportation or transfer of material from one
point to the next. Efficiency of the move as well as the safety factor in this dimension
is of prime concerns. The quantity per move dictates the type and nature of the
material handling equipment and also cost per unit for the conveyance of the goods.
The time dimension determines how quickly the material can move through the
facility. The amount of the work in process, excessive inventories, repeated handling
of the material, and order delivery lead times are affected by this aspect of the material
handling systems. The space aspect of the material handling is concerned with the
required space for the storage of the material handling equipment and their movement,
as well as the queuing or the staging space for the material itself. The tracking of the
material, positive identification, and inventory management are some aspects of the
control dimension. Material handling is also an integral part of plant layout. They
cannot be separated. A change in the material handling system will change the layout,
and a layout change will change the material handling system.
Material can be moved by hand or by automatic methods, material can be
moved one at a time or by the thousands, material can be located in a fixed location or
at random, or material can be stored on the floor or high in the sky. The variations are
limitless and only by cost comparison of the many alternatives will the correct answer
emerge.
The proper material handling equipment choice is the answer to all our
questions in this section. A material handling equipment list will include over 500
different types (classifications) of equipment, and if we multiply this number by the
different models, sizes, and brand names, several thousand pieces of equipment are
available for our use.
Material handling equipment has reduced the drudgery of work. It has reduced
the cost of production and has improved the quality of work life for nearly every
person in industry today.
But the handling of material is attributed to more one-half of all industrial
accidents. Material handling equipment can eliminate manual lifting and also can
cause injury, so do not forget about safety aspects.
II.6.5.2. Goals of Material Handling

The primary goal of material handling is to reduce unit costs of production. All
other goals are subordinate to this goal. But the following sub-goals are a good
checklist for cost reduction:
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1. Maintaining or improve product quality, reduce damage, and provide for

protection of materials.
2. Promote safety and improve working conditions.
3. Promote productivity:
a. Material should flow in a straight line.
b. Material should move as short a distance as possible.
c. Use gravity! It is free power.
d. Move more material at one time.
e. Mechanize material handling.
f. Automate material handling.
g. Maintain or improve material handling/production ratios.
h. Increase throughput by using automatic material handling equipment.
4. Promote increased use of facilities:
a. Promote the use of the building cube.
b. Purchase versatile equipment.
c. Standardize material handling equipment.
d. Maximize production equipment utilization using material handling
feeders.
e. Maintain, and replace as needed, all equipment and develop a
preventive maintenance program.
f. Integrate all material handling equipment into a system.
5. Reduce tare weight (dead weight)
6. Control inventory
II.6.5.3. The 20 Principles of Material Handling

The College Industrial Committee on Material Handling Education, sponsored
by the Material Handling Institute, Inc. and the International Material Management
Society has adapted the 20 principles of material handling.
The principles are guidelines for the application of sound judgment. Some
principles are in conflict with others, so only the situation being designed will
determine what is correct. The principles will be a good checklist for improvement
opportunities.
1. Planning principle. Plan all material handling and storage activities to obtain
maximum overall operating efficiency.
2. System principle. Integrate as many handling activities as is practical into a
coordinated system of operations, covering vendor, receiving, storage,
production, inspection, packaging, warehousing, shipping, transportation, and
customer.
3. Material flow principle. Provide an operation sequence and equipment layout
optimizing material flow.
4. Simplification principle. Simplify handling by reducing, eliminating, or
combining unnecessary movement and/or equipment.
5. Gravity principle. Utilize gravity to move material wherever practical.
6. Space utilization principle. Make optimum utilization of building cube.
7. Unit size principle. Increase the quantity, size, or weight of unit loads or flow
rate.
8. Mechanization principle. Mechanize handling operation.
9. Automation principle. Provide automation to include production, handling, and
storage functions.
Rezza Prayogi 2-17

10. Equipment selection principle. In selecting handling equipment, consider all

aspects of the material being handled – the movement and the method to be
used.
11. Standardization principle. Standardize handling methods as well as types and
sizes of handling equipment.
12. Adaptability principle. Use methods and equipment that can best perform a
variety of tasks and applications where special purpose equipment is not
justified.
13. Dead weight principle. Reduce ratio of dead weight of mobile handling
equipment to load carried.
14. Utilization principle. Plan for optimum utilization of handling equipment and
manpower.
15. Maintenance principle. Plan for preventive maintenance and scheduled repairs
of all handling equipment.
16. Obsolescence principle. Replace obsolete handling methods and equipment
when more efficient methods or equipment will improve operations.
17. Control principle. Use material handling activities to improve control of
production inventory and order handling.
18. Capacity principle. Use handling equipment to help achieve desired production
capacity.
19. Performance principle. Determine effectiveness of handling performance in
terms of expense per unit handled.
20. Safety principle. Provide suitable methods and equipment for safe handling.
II.6.5.4. The Material Handling Problem Solving Procedure

Step 1. Analyze the requirement to define the problem. Be sure the move is
required.
Step 2. Determine the magnitude of the problem. Cost analysis is best.
Step 3. Collect as much information as possible-why, who, what, where, when, and
how
Step 4. Search for vendors. Suppliers often provide outstanding engineering and
cost justification assistance.
Step 5. Develop variable alternatives
Step 6. Collect costs and savings data on all alternatives.
Step 7. Select the best method.
Step 8. Select a supplier.
Step 9. Prepare the cost justification.
Step 10. Prepare a formal report.
Step 11. Make a presentation to management.
Step 12. Obtain approvals (adjust as needed).
Step 13. Place an order.
Step 14. Receive and install equipment.
Step 15. Train employees.
Step 16. Debug (make it work) and revise as necessary.
Step 17. Place into production.
Step 18. Follow up to see what it is working as planned.
Step 19. Audit performance to see that payback was realized.
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II.6.5.5. Material Handling Equipment
II.6.5.5.1. Type of Material Handling Equipment

There are literally thousands of pieces of material handling devices. These
equipments vary from the most basic manual tools to the most sophisticated computer-
controlled material handling systems that can incorporate a vast array of other
manufacturing and control functions. Almost as varied and numerous are the
classification strategy and methods of material handling equipment.
Traditionally, material handling equipment may be grouped into four general
categories. The first category is the fixed-path or point-to-point equipment. This class
of equipment serves the material handling need along a predetermined, or a fixed path.
The most common and familiar example of a fixed-path system is the train and the
railroad track. The train can travel from any point to any point and serve any point
along the track system. Conveyor systems, powered, gravity-fed, or otherwise
operated, fall into this classification. Fixed-path material handling systems are also
referred to as continuous flow systems. Automated guided vehicles (AGV) fall into this
group.
The fixed-area material handling system can serve any point within a three-
dimensional area of cube. A jib crane or a bridge crane would serve as an example to
describe this category of material handling systems. A jib crane installed on a floor
pedestal can move parts and other material from any point in the x, y, and z direction;
however, this ability is limited within confines of the equipment. Automated storage
and retrieval systems (ASRS) also fall into this category.
The material handling equipment that can move to any area of the facility is
referred to as variable-path variable-area equipment. All manual cars, motorized
vehicles, and fork trucks can be pushed, dragged, or driven throughout the plant.
What, then, would a jib crane that is installed on a mobile pedestal be called?
Obviously, this is a compound material handling system. The crane is a fixed-area
system and the pedestal is a variable-path vehicle. When the base is stationary the
crane is confined within its reach.
The forth category consists of all auxiliary tools and equipment such as pallets,
skids, automatic data collection systems, and containers.
How do we choose the proper piece of equipment from the thousands of
material handling devices available to us? For the experienced project engineer or
manager, this problem is not as great as it is for the novice. To assist the new facilities
planner, the following organization of material handling equipment is suggested. This
organization follows the flow of material from the receipt of material to the
warehousing of that material as follows:
1. Receiving and shipping (they are similar)
2. Stores
3. Fabrication
4. Assembly
5. Packaging
6. Warehousing
This organization lends itself to specific problem-solving situations. Two additional
areas of material handling are:
7. Bulk material handling
8. Automatic storage and retrieval systems
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The systems principle of material handling states that material handling

devices should be used in as many as possible and that everything fits (works)
together.
II.6.5.5.2. Bulk Material Handling

Bulk Material Handling is an engineering field that is centered around the
design of equipment used for the transportation of materials such as ores and cereals in
loose bulk form. It can also relate to the handling of mixed wastes.
Bulk material handling systems are typically comprised of moveable items of
machinery such as conveyor belts, stackers, reclaimers, bucket elevators, shiploaders,
unloaders and various shuttles, hoppers and diverters combined with storage facilities
such as stockyards, storage silos or stockpiles.
The purpose of a bulk material handling facility is generally to transport
material from one of several locations (i.e. a source) to an ultimate destination.
Providing storage and inventory control and possibly material blending is usually part
of a bulk material handling system.
Bulk material handling systems can be found on mine sites, ports (for loading
or unloading of cereals, ores and minerals) and processing facilities (such as iron and
steel, coal fired power stations refineries).
In ports handling large quantities of bulk materials continuous ship unloaders
are replacing gantry cranes.
Figure II.8. Seattle Smith cove grain terminal
II.6.5.5.3. Forklift truck

A forklift truck, a lift truck, a High/Low or a forklift and sideloader is a
powered industrial truck used to lift and transport materials, normally by means of
steel forks inserted under the load. Forklifts are most commonly used to move loads
stored on pallets. The forklift was developed in the 1920s by various companies
including the transmission manufacturing company Clark (today known as Clark
Material Handling Company) and the hoist company Yale & Towne Manufacturing
(today known as Yale Materials Handling Corporation)[1]. It has since become an
indispensable piece of equipment in manufacturing and warehousing operations.
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Figure II.9. Forklift with Driver
There are many national and/or continental associations related to the industrial
trucks. The three major ones are the Industrial Truck Association (North America), the
Fédération Européenne de la Manutention (Europe), and the Japan Industrial Vehicles
Association (Japan). There are many significant contacts among them and they have
established joint statistical and engineering programs. One program is the WITS
(World Industrial Trucks Statistics) published every month to the association
memberships. The statistics are separated by area (continent), country, and class of
machine. While the statistics are generic, and do not count production from most of
the smaller manufacturers, the information is significant for its depth. These contacts
have brought to a common definition of the Class System, which all the major
manufacturers adhere to. Following is the list of the more common truck types, from
the smallest to the biggest:
 Hand pallet truck (a "pump truck", or a "chep truck", or a "hand-jack", a simple

mechanism whereby hand-pumped hydraulics raise or lower a single pallet
simply to provide clearance from the floor for manual (hand) pulling; heavy
loads are unwieldy or risk injury to operators.) (Separate article to follow with
photographs.)
 Walkie low lift truck (powered pallet truck, usually electrically powered)
 Rider low lift truck
 Towing tractor
 Walkie stacker
 Rider stacker
 Reach truck (small forklift, designed for small aisles, usually electrically
powered)
 Electric counterbalanced truck
 IC counterbalanced truck
 Sideloader
 Telescopic handler
 Slip Sheet machine
 Walkie Order Picking truck
 Rider Order Picking truck (commonly called an "Order Picker"; like a small
forklift, except the operator rides up to the load and transfers it article by
article)
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 Articulated Very Narrow Aisle Counterbalanced trucks (commonly called

"Bendi Truck")
 Guided Very Narrow Aisle truck - 'Man Down' (a type of reach truck designed
for aisles less than five feet wide) and 'Man Riser' Combination Order Picker/
Stacker truck
Figure II.10. Forklift Classes and Lift Codes
A typical 'Counterbalance' forklift may be generally described as follows:

 The truck proper, which is a motive machine with wheels and/or tracks
powered through a drive train.
 A liquefied petroleum gas–, petrol- or diesel fueled internal combustion
engine, or an electric motor(s) either direct current or alternating current
powered by either a battery or fuel cells.
 The mast, which is the vertical assembly that does the work of raising,
lowering, and tilting the load; the mast is either hydraulically operated
consisting of one or more cylinder(s) and interlocking rails for lifting and
lowering operations and for lateral stability, or it may be chain operated with a
hydraulic motor providing motive power.
Rezza Prayogi 2-22

 The carriage, which comprises flat metal plate(s) and is moved along the mast
either by means of chains, or by being directly attached to the hydraulic
cylinder.
 One or more forks, which are the L-shaped members that engage the load. The
back vertical portion of the fork attaches to the carriage most often by means of
a hook or latch (Class I to IV forks), while some forks use a shaft mount. The
front horizontal portion (which is usually tapered for ease of insertion) is
inserted into or under the load, usually on a pallet (also known as a "skid").
Alternatively, a variety of other equipment is available, including slipsheet
clamps, carton clamps, carpet rams, pole handlers, container handlers, roll
clamps and others.
 A load back rest is fitted when the load is higher than the top of the carriage,
and is a rack-like extension either bolted or welded to the carriage to prevent
the load from shifting backward.
 Rider operated machines have a driver's overhead guard, which is a metal roof,
supported by posts, that helps protect the operator from any falling objects.
 The cab, which may contain a seat for the operator, along with the control
pedals, steering wheel, levers, and switches for controlling the machine and a
dashboard containing operator readouts. The cab may be open, or closed, but is
bounded by the cage-like overhead guard assembly.
 Counterbalance machines have a counterweight, which is a heavy iron mass
attached to the rear of the machine, necessary to compensate for the load. In an
electric forklift, the large lead-acid battery itself may serve as part of the
counterweight.
 At the other end of the spectrum from the Counterbalance truck are more 'high
end' specialist trucks such as:
 Articulated Counterbalance Trucks
These are, unlike most other lift trucks, front wheel steer, and are a hybrid
VNA (Very Narrow Aisle) truck designed to be both able to offload trailers
and place the load in narrow aisle racking. Increasingly these trucks are able to
compete in terms of pallet storage density, lift heights and pallet throughput
with Guided Very Narrow Aisle trucks.
 Guided Very Narrow Aisle trucks
Figure II.11. Diesel Electric Forklift handling logs
These are rail or wide guided and available with lift heights up to 12 metres
(40') non top-tied and 30 metres (98') top-tied. Two forms are available; 'man-down'
Rezza Prayogi 2-23

and 'man-riser' where the operator elevates with the load for increased visibility or for
multilevel 'break bulk' order picking. This type of truck, unlike Articulated Narrow
Aisle Trucks, requires a high standard of floor flatness.
Forklift trucks are available in many variations and load capacities. In a typical
warehouse setting most forklifts used have load capacities of around one to five tons,
though machines of over 50 tonnes capacity have been built and operated. Unlike cars,
forklifts are normally rear-steer.
In addition to a control to raise and lower the forks (also known as blades or
tines), the operator can tilt the mast to compensate for a load's tendency to angle the
blades toward the ground and risk slipping off the forks. Tilt also provides a limited
ability to operate on non-level ground. Some machines also allow the operator to move
the tines and backrest laterally (side-shift), allowing easier placement of a load. To aid
the handling of skids that may have become excessively tilted and other specialty
material handling needs, some forklifts are fitted with a mechanism that allows the
tines to be rotated. In addition, a few machines offer a hydraulic control to move the
tines together or apart, removing the need for the operator to get out of the cab to
manually adjust for a differently sized load.
Roll and barrel clamp attachments for handling barrels, kegs, or paper rolls
also have a control to operate the clamp pads that grab the load, such attachments also
usually have a rotate function so that a vertically stored paper roll can be inserted into
the horizontal intake of a printing press.
In some locations (such as carpet warehouses) a long metal pole is used instead
of forks to lift large rolls. Similar devices, though much larger are used to pick up 40
tonne metal coils.
Another variation, used in some manufacturing facilities, utilizes forklift trucks
with a clamp attachment that the operator can open and close around a load, instead of
forks. Products such as cartons, boxes, etc., can be moved with these trucks. The
product to be moved is squeezed, lifted, and carried to its destination. These are
generally referred to as "clamp trucks".
Skilled forklift operators annually compete in obstacle and timed challenges at
regional forklift rodeos
Standards
Forklift safety is subject to a variety of standards world wide. The most
important standard is the ANSI B56—of which stewardship has now been passed from
the American National Standards Institute (ANSI) to the Industrial Truck Standards
Development Foundation after multi-year negotiations. ITSDF is a non-profit
organization whose only purpose is the promulgation and modernization of the B56
standard.
Other standards have been promulgatd by the U.S Occupational Safety and
Health Administration and the United Kingdom's Health and Safety Executive. Lift
truck operators must be trained and certified.
General
Forklifts are rated for loads at a specified maximum weight and a specified
forward centre of gravity. This information is located on a nameplate provided by the
manufacturer, and loads must not exceed these specifications. In many jurisdictions it
is illegal to remove or tamper with the nameplate, without the permission of the
forklift manufacturer.
An important aspect of forklift operation is that many have rear-wheel steering.
While this increases maneuverability in tight cornering situations, it differs from a
Rezza Prayogi 2-24

driver’s traditional experience with other wheeled vehicles as there is no caster action;
it is unnecessary to apply steering force to maintain a constant rate of turn.
Another critical characteristic of the forklift is its instability; the forklift and
load must be considered a unit, with a continually varying centre of gravity with every
movement of the load. A forklift must never negotiate a turn at speed with a raised
load, where centrifugal and gravitational forces may combine to cause a disastrous tip-
over accident. The forklift will be designed with a load limit for the forks, which is
decreased with fork elevation and undercutting of the load (i.e. load does not butt
against the fork "L"). A loading plate for loading reference is usually located on the
forklift. A forklift must not be used as a personnel elevator without the fitting of
specific safety equipment, such as a "cherry picker" or "cage".
Figure II.13. Load Capacity Chart
II.6.6. Cost Calculation
II.6.6.1. How Much Will Our Product Cost?

At the earliest point in a new product development project, the anticipated cost
must be determined. A feasibility study will show top management the profitability of
a new venture. Without proper, accurate costs, the profitability calculations would be
nothing but a guess.
Product costs consist of:

Typical %
Manufacturing costs Direct labor 8

50% Direct materials 25
Overhead costs 17
Front-end costs Sales&Distribution costs 15
Advertising 5
Administrative overhead 20
50% Engineering 3
Profit 7
100%
Direct labor cost is the most difficult component of product cost to estimate.
Time standards must be set prior to any equipment purchase or material availability.
Time standards are set using predetermined time standards or standard data from
blueprints and workstation sketches. The time standards are collected on something
like the operations chart.
Rezza Prayogi 2-25

Direct material is the material that makes up the finished product and is
estimated by calling vendors for a bid price. Normally, 50% of the manufacturing cost
(direct labor + direct materials + factory overhead) is direct material cost. On the
operating chart, raw materials are introduced at the top of each line. Buyout parts are
introduced at the assembly and Packout station.
Factory overhead costs are all expenses of running a factory, except the
previously discussed direct labor and direct material. Factory overhead is calculated as
a percentage of direct labor. This percentage is calculated using last year’s actual
costs.
Labor cost is the most difficult cost to calculate of all the costs that make up
the selling price. How could you calculate the selling price without time standards?
Anything else is a guess.
Cost-estimating is an important part of any industrial engineering program and
should be a complete course covering operations, product, and project costing. Motion
and time study would, of course, be a prerequisite.
II.6.6.2. Material Handling Cost

Material handling equipment can be very expensive, so all investments should
be cost-justified. The lowest overall cost per unit gives us the best answer. If a very
expensive piece of equipment reduces unit cost, it is a good purchase. If it does not
reduce unit cost, it is a bad purchase.
Non-powered equipment can be very cost efficient and should always be
considered. Gravity chute, rollers, hand carts, and hand jacks are only few of the many
very popular methods of moving material economically.
Safety, quality, labor, power, and equipment costs must all be included in the
unit costs. If someone is expected to lift a 100lbs load while performing a task, the
long term effect of the activity, or the cumulative trauma disorder, associated with this
job must be considered. Ergonomic consideration of job design dictates that some type
of material handling system such as a hydraulic or pneumatic lifting device should be
studied. If taken in isolation, the dollar cost may not be justifiable; however, the long-
term safety considerations will certainly prove the investment to be a wise one. An
automobile manufacturer discovered that a simple manipulator device, which assisted
in lifting and turning the car seats while installing them, prevented serious and chronic
lower back pain and injury to the assembly line workers.
II.6.6.3. Cost Reduction Formula

The cost reduction formula is valuable when working with manufacturing
facilities design and material handling. The cost reduction formula is a word formula
that looks like this:
Ask For Every So We Can
Why Operation Eliminate
Who Transportation Combine
What Inspection Change sequence
Where Storage Simplify
When Delay
How
We ask the six questions (column one) about everything that can happen to a
part flowing through our manufacturing facility (column two) so that we can eliminate
steps, combine steps, change sequence of steps, or simplify (column three). This
requires that we study the product of our company in order to identify every step in the
process. This is a big job and is why the company will pay you the big bucks. The best
Rezza Prayogi 2-26

advice you can get is not to take shortcuts or to skip steps in the proposed
manufacturing facility design procedure. There is no easy way, just hard work and
attention to detail.
The five (5) S’s and five why’s are also cost reduction attitudes that will help
to reduce costs. The 5 S’s principles are:
1. Sifting (organization). Keeping the minimum of what is required will save
space (affects the facility layout), inventory, and money.
2. Sorting (arrangement). Everything has a specific place, and everything in its
place is a visual management philosophy that affects the facility layout.
3. Sweeping (cleaning). A clean plant is a result of a facility layout that has been
thought to provide room for everything.
4. Spick and span (hygiene). A safe plant is a result of good layout planning.
5. Strict (discipline). Following the procedures and standardized methods and
making them a habit will keep the plant operating efficiently and safely.
The five ―why’s‖ is a way of thinking that will ensure that the solution to a
problem is not a symptom of the problem, but rather, the base cause. For example: we
had a machine break down. Why?
1. The machine jammed up. Why?
2. The machine was not cleaned. Why?
3. The operator did not clean it out at regular intervals. Why?
4. Lack of training? Why?
5. The supervisor forgot. They make a written instruction to be mounted on the
machine. It will not happen again.
We could have asked six or seven why’s – the important thing is to arrive at a final
solution that will eliminate the problem from occurring again.
II.6.7. Tips
Here are some tips from me on how to make this facilities planning run faster,
more efficient, and decrease error.
1. Design Product use Solidworks or CATIA.
2. Takt time, scrap rates, process design, space, cost calculation use Excel.
3. Plant layouts use Visio Template.
4. Process Design and Factory Simulation using Delmia.
5. Material Handling and Production equipment data, search in product catalog
II.7. How to Build Digital Factory

II.7.1. Getting Started with Delmia Quest
II.7.1.1. Introduction
The QUEST discrete event simulation package is a very powerful simulation
tool that will allow you to model and analyze complex systems. In this sub-chapter we
will discuss the best ways to begin using QUEST. Topics covered include starting
QUEST and the options available at startup, the file system and user interface, and the
various controls and navigation tools provided in the product. I want to show you how
to start Delmia QUEST, load a model, and navigate through the various menus and
controls.
QUEST runs on both UNIX and Windows based systems. The user interface is
similar between platforms, with minor differences taking advantage of the specific
strengths of each platform. It only works in Windows NT systems include in these NT
categories: Windows NT, Windows 2000, Windows XP, Windows Vista, and not in
Windows 95 and Windows 98.
Rezza Prayogi 2-27

II.7.1.2. Starting QUEST

The installation process will create a menu item under Programs in your Start
menu in the Windows version. It will also place a shortcut on your desktop.
QUEST is launched with a batch file (Windows) or script (UNIX). The batch file sets
the various environment variables and then invokes the executable file that starts QUEST. The
batch file is called quest .bat (Windows) or quest (UNIX) and is found in the
DELMIA/quest directory. Shown below is the standard quest .bat file for the Windows
platform.
@echo off
set DELMIA_PRODUCT=QUEST
set DELMIA PATH=C:\DELMIA
_
set PROD_LIB=%DELMIA_PATH%\%DELMIA_PRODUCT%\
if ”%TMP%” == ”” set TMP=C:\tmp

if ”%TMPDIR%” == ”” set TMPDIR=C:\tmp
set LM _LICENSE _FILE= %DELMIA_PATH%\license\license.dat
set
VIEWER _PROG=C: \PROGRA~1\Netscape\NAVIGA~1\Program\Netscape .exe
set DELMIA_DOC_VIEWER=%VIEWER_PROG%
%PROD_LIB%docs\%DELMIA_PRODUCT%_HOME\HOMEPAGE . html
cd %PROD_LIB%
echo initializing and running % DELMIA_PRODUCT%
start /max %DELMIA_PRODUCT%.exe %1 %2 %3 %4 %5 %6 %7 %8 %9
There are a number of setup options that you can configure in order to
customize the way QUEST starts. Customizing your startup can significantly reduce
the time it takes to get started each day. It is also useful in creating a predefined format for
organizing libraries and loading models.
If you wish to locate QUEST or any of its components under a different
directory structure then you will need to make these changes when the product is
installed. It is not advisable to move the QUEST system or data files after the product
has been installed.
Modifying the quest .bat file shown above generally creates a customized
startup. The last line that launches the %DELMIA_PRODUCT%.exe takes in up to
nine arguments. These are indicated by the %1 through %9 shown above. These
options may be invoked by supplying the arguments to the quest .bat file in the
command prompt or by deleting the %1 through %9 in the batch file and keying in
the desired argument. For example, to launch QUEST with a specific license file the
last line of the quest .bat file is modified as shown below:
start /max %DELMIA_PRODUCT%.exe –L 530
This instructs QUEST to use license number 530.

The various options that you can invoke when launching QUEST are shown
below:
 -AA <mode> - Launches QUEST on an SGI RealityEngine workstation
using anti-aliasing. The optional <mode> value is 4, 8, or 16 and is the
number of pixel samples that the hardware uses when rendering. The higher
the number, the better the quality of the anti-aliasing but performance will be
Rezza Prayogi 2-28

lower. Default value for <mode> is 4.

 -f - Starts QUEST in full screen mode.
 -i <string> - QUEST loads with the specified string as the window and
icon title. When used on the command line, <string> cannot contain any blank
characters. If this option is specified inside of the startup script, a multiword
string can be specified using single quotes, i.e., -i 'Version 2.4'.
 -r <filename> - Automatically loads the specified model upon startup.
The .qpthfig should include all necessary configuration files.
 -v <xmin> <xmax> <ymin> <ymax> (Viewport) - Launches QUEST with
the screen viewport set based on the four parameters entered. The first two
parameters represent the X dimension of the screen. The second two parameters
represent the Y dimension. The zero-zero point for the window is located at
the bottom, left-hand corner of the screen. The parameter values are ratios.
For the X parameters, they are the ratio of the desired window height to the
screen resolution. For the Y parameters, they are the ratio of the desired
window width to that of the screen. This is useful when you want to work
in a window of a specific size. For example, when you wish to create a
NTSC video from a 1280*1024 resolution monitor, the command line
would be %DELMIA2PRODUCT%.exe -v 0.0 0.5 0.0 0.46875, resulting
in a window of 640*480 resolution. On a Windows platform this option is the
same as the -w option below. On a Unix platform the -v option will not create
a window, hence it cannot be minimized or moved.
 -b - To start QUEST in the batch mode and immediately invoke a BCL
file.
 -s - To launch QUEST in the socket mode to allow communication with
other processes on the computer or network.
 -w <xmin> <xmax> <ymin> <ymax> (Window) - To run QUEST in a
user-sized window in a specified location on the screen. This option includes
full borders which allows the window to be sized, moved, and iconized. It
is specified by the four parameters following the -w option, which are
floating point numbers in the range [0.0 ... 1.0].
 -L <license number> - Launches QUEST with the specified license
number.
 CONFIGS/Configname - Adding the library configuration file name of
a particular project will immediately append the relevant project upon
launching QUEST. Although this is a valid startup option, it is advisable to
append all required library configuration files through the .qpthfig file.
 Path to .qpthfig file - This forces QUEST to use this particular .qpthfig
instead of looking for one in the user's home directory.
Rezza Prayogi 2-29

II.7.1.3. Configuration Files

The configuration file (config file) mechanism controls the information
that QUEST uses when it loads up and it controls how QUEST uses data for
reading and writing. It provides a flexible way to organize data and re-use data
in different models. It also provides an easy mechanism for moving models from
one computer to another.
QUEST stores all of its model-related data in a set of directories known as the
Configuration Library. For example, geometries used in the model are stored in the
PARTS directory, kinematics are stored in the KINEMATICS directory and so on. This
method of storing data in different directories permits re-usability of data in different
models. The location of the configuration library (and all its sub-directories) is
stored in a file called the Library Configuration File or configs file. A configs file is thus an
ASCII text file that contains a series of configs file directory specifications. The syntax of a
configs file directory specification is:
SYNTAX:
<path type>$LIB = <path name file path name>
EXAMPLE:
KINEMATICS$LIB = C:\DELMIA\QUESTlib\KINEMATICS (Windows)
PART$LIB = /usr/ DELMIA/QUESTlib/PARTS (UNIX)
When a configuration file is read by QUEST, the configs file directory specifications
are made available to QUEST. This is how QUEST knows where to look for each type of
data that it needs, e.g., model files, logic files, default geometries, etc. It is advisable not to
store any of your models in the default QUEST1ib or quest directories. These should be
write-protected and read-only since any modification to these folders will change the default
behavior of QUEST.
NOTE: When you start a new simulation project with QUEST it is
always a good idea to create a separate library for that project and
save all of the project related information there.
Apart from the library configuration files mentioned above, there are three special types of
configs files that may be created and used with QUEST. They are:
 .qpthfig - This is the QUEST Path Configuration file and is accessed through
File Edit Config File. This is where you define a CONFIG$LIB that points
to a specific directory on your computer where all your QUEST library
configuration files are stored. You may also include specific configs files in
the .qpthfig so that these libraries are automatically appended when QUEST is
launched. Example .qpthfig file:
CONFIG$LIB = c:
/Projects/MyQuestConfigs/ Include quest
Include Proj ectA. cfg
Include AgvProj ect. Cfg
NOTE: When you include specific config files (as done above) it is
assumed to be in the SAME directory as specified in the
CONFIG$LIB In the above example, the library configuration files
named ProjectA.cfg and AgvProject.cfg are assumed to lie in the
directory c:/Projects/MyQuestConfigs/.
 .qenvfig - This is the QUEST environment configuration file and is accessed
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through File Edit Config File. This is where all your QUEST environment
specific preferences are stored. The QUEST environment includes settings such
as cursor style, floor color, background color, grid size, font size, etc. This file
is created when File Save Config File is selected. All the current preferences
will be stored and used every time QUEST is launched subsequently.
• .qbutfig - This is the QUEST button configuration file and is created
when you select User Save. This is where the user button information is
saved.
None of the three configuration files described are shipped with QUEST and the
user must create them. They should be located in your home directory. The simplest
method of determining the home directory is to allow QUEST to figure it out by
editing/creating these files inside QUEST (use the File Edit Config File option and select
the "Write" button to save the file when done).
II.7.1.4. The User Interface

The user interface is designed to allow you to navigate within the product with the
minimum number of keystrokes, while providing an easy-to-use and consistent approach.
Shown below is the screen you are presented with when you first start QUEST (on Windows).
Figure II.14. Delmia Quest user interface
The user interface is split into five general areas on the screen as shown above.
Models themselves are shown in the middle part of the screen. The menus (or contexts on Unix)
at the top of the screen connect you to the broad areas of functionality in QUEST. These are
defined in detail in the chapters ahead, but they are summarized here as an introduction.
The pages on the right of your screen are displayed according to the menu item you
choose. These pages in turn contain a group of action buttons that provide specific functions in
the product. Note that in the following discussions the terms menu and context, menu items
and pages are used interchangeably, but refer to the same function.
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The world controls give you the functionality to manipulate and move around the
world (Model, CAD or Draw) that you are currently working with.
II.7.1.5. Pull Down Menu (Context Button)

There are ten menus (contexts) in QUEST. Selecting one will activate a pull-
down menu, showing a series of items (on Unix, buttons are shown on the right hand
side) and are invoked by clicking on the relevant item. For example, selecting the
Model menu will show a number of items such as Build, MHS, Layout, etc. On
Unix systems, this user interface is known as the three-tier interface.
The menus cover the following areas:
File
The file menu has file handling functions including loading and saving
models (with the same name or different name), creating and appending libraries,
and generally manipulating files.
Model
This is the main model development menu that permits element and class
creation, connections, 2D modeling, and process creation.
Advanced
This menu includes auxiliary model building menu that permits creation and
manipulation of groups, popups, kinematics, and display settings.
Run
Run provides a number of controls to run and debug the simulation, and analyze
the performance of the system by gathering various statistics and reports.
CAD
CAD is used to import, create or modify the geometrical representations of the
logical elements in the model. QUEST provides a set of data translators so that
layouts and components may be imported from other 2D or 3D CAD
software packages.
Draw
Draw is used for the creation or modification of 2D geometries.
Tools
The Tools menu provides a series of functions including dimensioning, measuring,
and lighting. The items on the Tools page are dependent on context that was invoked
before the Tools context was invoked. The Windows functionality is located under
the Tools menu.
User
The User menu provides a series of user pages that you can customize. The user pages
provide two distinct options for customization. User buttons permit the duplication of
any other button in the interface. This is very useful when you have a limited number of
functions that you use very often, but they are spread over a number of different pages.
These buttons may be collected and placed together on a user page for quicker access.
User buttons can also invoke SCL or BCL macros.
Pref
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Pref allows you to setup preferences such as color, button style, grid size, and level of
detail. This menu thus provides options to change the look and feel of QUEST.
Help
The help menu allows you to access the QUEST online help documentation and the
button help. It also lets you determine the current QUEST version, license number,
options installed, and current user information.
II.7.1.6. World Control Button

The World Control Buttons shown below provide a combination of dialog boxes
and functionality to manipulate the way in which the current world (Model, CAD, or
Draw) is displayed. This functionality is summarized below.
Figure II.15. World Control Button
Light
QUEST provides a number of lights that can be positioned and turned on to provide
enhanced reality and shadowing effects. The Lights page allows the manipulation of the
position of these light sources. After clicking on the Lights button you can then move
the mouse with either the left or middle mouse buttons held down to change the angle
and elevation of the light source relative to the current center of interest. This button
works only when Pref Shadow button is toggled on.
Camera
Clicking on the Camera button invokes the Camera Options dialog box and
resulting dialog boxes as shown below.
Figure II.16. Camera dialog box
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 Camera Specs - This selection allows you to set the projection type
(orthographic or perspective), the image plane size, focal length and the field of
view. It controls the perception of distance while looking at the model.
 Tracking - This selection allows you to set the center of view onto a part or
frame. As you run the simulation the part or frame will be maintained at the
center of view. This is particularly useful when you want to follow a
particular part as it moves through a model. The Cruise or Rotate world
display buttons may not be used when tracking is switched on.
 Mounting - This selection allows you to mount the camera on a part, frame
(coorsys), or surface. Once selected, the camera is snapped to the relevant place
and moves with the entity to which it is now attached. The "Grab by Part"
selection causes the camera to be mounted in its current position relative to the
selected part, and as that part moves the camera will move to maintain the
same position relative to the part.
 Pan/Tilt - This selection gives you the ability to pan/tilt the camera using the
right mouse button (RMB) and to change the field of view using the middle
mouse button (MMB). Clicking on a specific point in the model with the
RMB immediately selects that point as the center of interest (COI).
 Locate - This selection allows you to translate the camera within the field of
view.
Invoking the Fly world display button creates a small box at the center of view. Dragging the
mouse with the left mouse button (LMB) held down will cause an acceleration towards the
center of view. The same action with the RMB will move you away from the center of view.
Use the MMB to aim the view point in any direction.
Rotate
Invoking the Rotate world display button and moving the mouse with one of the left/middle/right
buttons pressed, will rotate the view around the center of the model. You can also type
rotations directly using the Reset and Abs buttons or snap the rotation by 90 degrees in
each direction with the Snap button.
Cruise
The cruise feature is the most commonly used tool for moving around the world. If you
move the mouse with the LMB held down, QUEST will rotate the camera about the
current center of interest (COI). Using the MMB will translate the camera directly
towards or away from the COI, this allows you to zoom in on a particular feature of interest
very quickly. The RMB provides two functions: If you hold down the RMB and move the
mouse, QUEST will trace a circle around the area of interest, as you release the RMB the
camera will zoom towards the selected area. If you click on a specific point with the RMB,
QUEST will select that point as the COI.
View
The View button provides a series of dialog boxes shown below, to create and retrieve a set
of standard camera positions for a model. The standard views list box provides set views
of the model based on the current center of interest. These are useful, especially when you
are operating with the camera in orthographic mode, for positioning elements in a
model.
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Figure II.17. User View dialog box
 Standard Views - This selection allows you to quickly set the view to one
of six system-provided standard views.
 User Views / User View Utilities - This selection allows you to create your
own views of the model. The User View Utilities allows you to save the
current view and invoking User Views will show all the user views that
you have saved so far. This combination is used when you wish to create a
choreographed walk through of a model either for presentations or for
digital output such as videos or AVIs.
 Display States / Display States Utilities - Allows you to capture the general
display conditions of a model at a particular time. Selecting Display States
presents a list of the display states that have been set up.
 Find Element - Allows you to locate a lost element in the world; which would
usually happen when the model happens to be a big one. This functionality
prompts the user to first select an element that they are looking for. The
selected element is then centered and magnified. The hither plane will also be
adjusted. The element will remain highlighted while the camera moves in on
the element. The number of steps is controlled by selecting the
Environment I Input button and changing the "Max Magnify Steps". All
other elements are made transparent at the end of the camera move. You
may still be required to do some cruising to fully see the selected element.
However, the element will be made the center of interest, so further zooming
should bring the element into view. If you select an element with no geometry,
like a path system, then a message will be issued.
Display
The Display button, in the Model world, invokes the World Display Mode dialog box
as shown below.
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Figure II.18. Display dialog box
 Render - This sets the render properties for all elements and parts in a model.
This will override the individual settings on parts or elements. The options are
default, flat, smooth, wire, and transparent. Setting the render to smooth will result
in a higher quality view, but requires more system resources. Wire converts
everything to wireframe mode, while transparent turns all elements to
transparent (that is, it will create a see-through effect for all geometries).
 The remaining selections turn the associated function on or off. Further discussion
of the World Display Mode dialog box is provided in Appendix A, The
QUEST User Interface.
Modes
The Modes world display button brings up the Model Modes dialog box shown below
and provides a series of options.
Figure II.19. Modes dialog box
 Multi Views - Allows you to split the screen into a number of views of the
same model. This is a powerful function in both the CAD and modelling
worlds. In CAD it can be very useful when you are working from 2D
drawings, for example DXF. In this case you can split the views into plan and
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elevation views to build up the 3D view. In the modeling world, split views
are useful when you need to look at a number of parts of your model at the same
time. You can cruise in each of the views independently.
 Stacking Mode - This determines whether one or all of the parts in a buffer
will be visible.
 Entity List Order - This defines the order in which the names of Via Points
appear in any entity selection dialog box for all Via Point selection options.
 Indicate Point - This defines the type of point picking when indicating points.
II.7.1.7. Using the Mouse

A three-button mouse is required for using QUEST. By now you should be able to start
QUEST and move through the general functions of the product. The three mouse buttons are a
vital part of the user interface and contribute significantly to the ease of use of the product.
See Appendix A, The QUEST User Interface for more information on entity selection, zip
mode, and point indication with using the mouse.
Translating or Rotating Elements

The left, middle, and right mouse buttons (LMB, MMB, RMB) are often linked to the x,
y, or z axis respectively. This works when you are manipulating an element or CAD part,
either using the Trn (translate) or Rot (rotate) buttons. In either case once the button is
selected, moving the mouse with the respective mouse button held down will move or
rotate the chosen element in one direction. If you select the Tmn or Rot buttons with the
RMB then the world will move to wireframe for the duration of the function. This allows
items to be manipulated more quickly.
ZIP Mode
Zip mode is the process of selecting a function with the RMB. Many functions have
intermediate steps. Using zip mode will skip intermediate functions where appropriate,
generally assuming that the intermediate steps are a repeat of a previous invocation. For
example: If the Run button is selected with the RMB, then the run begins immediately
using previously entered values for the Run Time dialog box.
Zip mode reduces the number of keystrokes. It is advisable not to use the zip mode until
you become familiar with QUEST.
II.7.2. Step by Step to Build Delmia Simulation
Introduction
This sub-chapter will introduce the basic modelling constructs used to develop
a QUEST simulation model. In this sub-chapter, the concepts of a part class and
element class are used to build a simple straight-through processing system.
A part class can be defined to create a number of parts having the same
properties. A part is an entity that moves between elements and is processed by the
system. Parts are generated at sources or as a result of a machine process. Parts are
consumed by sinks or as a result of a machine process.
Similarly, an element class can be defined to create a number of elements
having the same properties. Elements are the basis of how QUEST models systems.
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Different types of elements include AGVs, AGV path systems, buffers, controllers,
conveyors, labor, power and free path systems, sources, sinks, and machines.
Displaying QUEST
Once QUEST is "launched", the QUEST window and QUEST 3D window
will use only about two-thirds of the screen. The 3D window is used for the three-
dimensional graphics simulation. For best visual results, expand the QUEST Window
and the 3D window to fill the screen.
Messages
The user is strongly encouraged to monitor the messages appearing in the
message window at every step throughout this step by step example. These messages
will confirm actions completed, prompt the user for additional action, or prompt the
user that an action is unsuccessful.
Set Up
1. Select the maximize button at the top right-hand corner to enlarge the QUEST
window. Select the same button in the QUEST 3D window to maximize the work area
window.
Figure II.20. Set up the window
2.
Figure II.21. Question to clear world from previous simulation
If QUEST was used previous to starting this model building session, the QUEST
world should be cleared and reset. To do this, select File | Clear World. When
prompted with ? Clear World ?, select Yes to confirm this selection.
3. While QUEST is clearing the system, the message window will display
"Reinitializing the System ..." When this is finished, the message window will display
"World cleared".
4. The next step is to Reset the world. Select File | Reset World. When prompted
with ?Reset World?, select Yes to confirm the selection.
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5.
Figure II.22. Change simulation time units
The proper time units need to be set. To do this, select Run | Simulate | Time Units.
Complete the Time Units dialog box as shown and click on OK.
6.
Figure II.23. Change unit
The proper distance units need to be set. To do this, select Tools | Measure | Units.
Choose the appropriate units as shown and click on OK.
Create a Part Class
A part class to be used in this model can be created. Select Model | Build | Part Class |
Create/Modify. Use the default settings in the Part Class dialog box and click on OK.
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Figure II.24. Part dialog box
Figure II.25. Sample Model with Elements
Create a Source
One source, which is an element as previously mentioned, will be created for this
model to serve as a mechanism by which the parts can enter the model.
1. Select Model | Build | Element Class | Source. The Source dialog box will appear.
Figure II.26. Source dialog box
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To define the inter-arrival time for the source, select the IAT button. Choose
Exponential from the Distributions list and click on OK. In the Exponential dialog
box, change the Mean to 25, and the Starting Stream to 1. Click on OK to close this
dialog box and click on OK in the Source dialog box.
The message window now displays "Element <Source1_1> Created. Select a location
on the floor/2D window for <Source1_1>."
NOTE: Source1 is the name of the class, while Source1_1 is the name of one source
which belongs to class Source1. In this particular step by step example only, one
source belonging to class Source1 will be created. Any number of sources belonging
to this class could be created if desired. In general, the only properties that are
different between multiple elements of the same class are their names, location, and
connections.
2. See Figure II.25 for the positions of the various model elements to be created in this
model. Use the world display buttons at the bottom of the screen (Rotate, Cruise,
View, etc.) to reorient the screen view in order to get an overall picture of the working
grid. Use the LMB and click on the approximate location where the source should be
positioned.
3. Select Model | Build | Element | Trn. Using the LMB, move the currently selected
Source1_1 across the grid along the X axis or, with the MMB, move along the Y axis
until Source1_1 is properly located. It is more important to place all the elements in a
specific relationship to one another rather than placing them in absolute locations. If
necessary, elements can be moved at a later time.
Create a Machine
Parts are created at the source and are processed on a machine. This machine will be
created next.
1. Select Model | Build | Element Class | Machine. The Machine dialog box will
appear.
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Figure II.27. Machine dialog box
Select the Cycle Process button to further define this machine.
2. Choose New Process in the Select Process dialog box. The Cycle Process
Definition dialog box will be displayed. Select the Cycle Time button.
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Figure II.28. Cycle process dialog box
3. Choose Normal distribution and click on OK. Enter a Mean of 25 and a Standard
Deviation of 5 secs. To maintain statistical independence set the Starting Stream
Value to 2 and click on OK. Click on OK on the Cycle Process Definition dialog box.
Click OK on the Machine dialog box. The message window will display:
Figure II.29. Message to put Machine on the Floor
As before, Machine1 is the name of the class, while Machine1_1 is the name of a
machine which is of the class Machine1. In this step by step example, only one
machine will be created; however, any number of machines could be created in the
class if necessary.
4. Select a location on the floor/2D window for Machine1_1. See Figure II.25 to see
where to place Machine1_1 in relationship to Source1_1. Its position can be corrected
later if necessary.
Create a Sink
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A sink will be created to collect the processed parts for their exit from the model.
1. Select Model | Build | Element Class | Sink. Leave the default settings on the Sink
dialog box and click on OK.
Figure II.30. Sink dialog box
2. One sink will be created named Sink1_1 as the first sink of class Sink1. Position
Sink1_1 as shown in Figure II.25.
Create Buffers
Two buffers will be created for this model: one between Source1_1 and Machine1_1,
and another between Machine1_1 and Sink1_1.
1. Select Model | Build | Element Class | Buffer. In the Buffer dialog box, change the
No. of Elements to 2 and leave all other values as is. Select the Display button. Set
the Color to any available value. In this instance, Brown was chosen. Click on OK in
the Display and Buffer dialog boxes.
Because the Display definition is for the Buffer1 class, both buffers will be brown.
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Figure II.31. Buffer dialog box
2. When prompted, position Buffer1_1 between Source1_1 and Machine1_1. Position

Buffer1_2 between Machine1_1 and Sink1_1. Use the Locate button or the Sel | Trn
to move any of the elements until they are in the proper relationship as shown in
Figure II.25.
Connect the Elements
With the basic process elements defined, the sequence of processes can be defined to
assure the proper flow of parts through the system. Connections are required between
each element to make this happen.
1. Select Model | Build | Connections | Element. The message window will prompt
for a starting element. With the LMB, pick Source1_1. When prompted, pick
Buffer1_1 as the ending element. This completes the first connection.
2. The message window will prompt for the starting point of the next connection. Pick
Buffer1_1, again, and when prompted to indicate the ending element, pick
Machine1_1. To complete the third connection, when prompted, pick Machine1_1 as
the starting element and pick Buffer1_2 as the ending element. The last connection is
to select Buffer1_2 as the starting element and Sink1_1 as the ending element.
Note that the dialog boxes, Select an Output Element, and Select an Input
Element have not been used. To remove the final Select an Output Element
dialog box, click on Cancel in the dialog box.
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If necessary, select the Model | Build | Connections | Show button and

proceed through the message window prompts to check the connections. A
window will appear showing the input and/or output of the selected element.
Save the Model
It is good practice to save the model throughout any model building process. There
are two ways to do this.
1. Select File | Save Model or File | Save Model As and save the model as
basic01.mdl in c:\deneb\QTUTORlib\MODELS
Or,
2. Select Model | Build | Model | Save and save the model as basic01.mdl in
c:\deneb\QTUTORlib\MODELS
Run the Simulation
1. To run the simulation, select Run | Simulate | Simulation | Run. Enter the values
as shown below, and click on OK. The simulation will run for 1000 seconds.
Figure II.32. Run simulation dialog box
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CHAPTER III
PROJECT AND CALCULATION
III.1. Introduction
The purpose of this chapter is to illustrate the systematic approach presented in
this master thesis for the design of a manufacturing facility using digital factory. The
project is broken into several segments, which presented in the proper sequence. Each
project segment utilizes the concepts, tools, and the various topics that are set close to
the theory presented in chapter 2 and will lead toward the design of a complete
manufacturing facility for the fabrication and assembly of a gas grill product. The
fictitious Gas Grill serves as a practical example of how to follow the approach and
apply the material and the tools covered in theory chapter 2 for the design of an
effective and an efficient manufacturing facility.
The beauty of facilities design lies in the fact that whereas an array of
qualitative and quantitative tools are available, and the design can be subjected and
evaluated through the use of numerous analytical means, there remains a significant
latitude to accommodate the planners creativity and vision. It is, therefore, quite
conceivable and even expected that different teams of facilities planners would arrive
at completely different designs for the production of the same products. Individual
differences, philosophies, visions, creativity, and even compromises will result in
variations in designs of the facility. These differences do not necessarily affect the
main objectives of the facility or adversely influences its functionality and
productivity, but simply result in varied and different outcomes in the design. Without
a doubt, some plant layouts are better than others. They adhere to all the goals of the
manufacturing facilities design, procedures for reduction of waste, and the principles
and practices of lean manufacturing. Of course, there are those that leave a lot to be
desired and provide the greatest opportunity for improvements.
I collect all data from Moryl GmbH where I make my internship for 8 month;
I collect data for machines, scrap rates, manufacturing time, material movement time,
time standards and a lot of historical data. This data are vital in determining
equipment and personnel requirements, balancing assembly lines, setting conveyor
belt speeds, estimating product cost, and so on.
III.2. Design of Gas Grill

In this sub-chapter, I will present the design of gas grill. As stated by theory, a
new facility should be started with a product that wants to be produce. This sub-
chapter usually created by Design Engineer Department, data for a new product (or
improved product) comes from marketing, sales, customer service departments,
because those department have an accurate data from our targeted customer.
With the aid of the various departments such as engineering, fabrication,
purchasing, the exploded view of the grill, the indented bill of materials,
manufactured purchased parts drawing and specifications are developed and here
presented. Scrap rate are obtained for various processes and departments based on
their historical data and sources of information.
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Figure III.1 Gas grill in 3D CAD view which created using Solidworks
Figure III.2 Gas grill in rendered view which created using Photoworks
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Figure III.3. Exploded view of my gas grill (for assembly purpose)
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Table III.1 Indented Bill of Material from my gas grill

Level Part No. Part Name Drwg. No. Qty/Unit Make/Buy
0 STG1 Packaged grill DWG1 1 M
1 PP1 Bottom grill casting PDWG1 1 B
1 PP2 Grease can wire PDWG2 1 B
1 PP3 Top grill casting PDWG3 1 B
1 PP4 Wood handle PDWG4 1 B
1 STG4 Legs DWG4 4 M
2 STG8 Top support DWG8 2 M
1 STG5 Tube plugs DWG5 4 M
1 STG6 Leg extensions DWG6 2 M
1 STG7 Wood slats DWG7 4 M
1 STG9 Bottom support DWG9 2 M
1 STG10 Tank holder DWG10 1 M
1 STG11 Axle DWG11 1 M
1 PP11 Wheels PDWG11 2 B
1 PP12 Hub caps PDWG12 2 B
1 STG12 Control panel DWG12 1 M
1 STG13 Knob DWG13 1 M
1 PP13 Ignitor PDWG13 1 B
1 PP14 Valve assembly PDWG14 1 B
1 PP15 Burner element PDWG15 1 B
1 PP16 Cooking grid PDWG16 1 B
1 PP17 Rock grate PDWG17 1 B
1 PP19 Heat shield PDWG19 1 B
1 PP20 Accessories bag PDWG20 1 B
2 PP5 10-24 x 1/2” bolts PDWG5 12 B
2 PP6 10-24 nuts PDWG6 3 B
2 PP7 Washer PDWG7 1 B
2 PP8 10-24 x 1 3/8” screws PDWG8 13 B
2 PP9 #6-32 x 3/8” bolt PDWG9 2 B
2 PP10 Cotter pin PDWG10 2 B
2 PP105 Pin PDWG105 2 B
III.3. Takt Time and Scrap Rates Calculation

In this sub-chapter, I calculate for takt time (R Value) or plant rate and scrap
rates for later use in manufacturing design and simulation. In this factory I will use 3
shifts with each shift include 8 hour working time.
8 hour shift × 60 minutes = 480 minutes
480 minutes
- 30 minutes lunch
- 10 minutes 1st break
- 10 minutes 2nd break
430 minutes total available (per shift)
430 minutes × 3 shifts = 1.290 minutes/day
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Assuming 75% plant efficiency:

1.290 minutes/day × 75% = 967,5 minutes/day
When we want to produce 1.500 grills per day:

967, 5 minutes/day ÷ 1.500 grills/day = 0,645 minutes/grill
From Table III.1, we just want to make 10 parts and for 1.500 gas grill/day, we need:
1. Legs : 1.500 × 4 = 6.000 legs/day
2. Wood slats : 1.500 grill/day × 5 = 7.500 wood slats/day
For wood slats actually 4 part per grill, but 1 wood for customer bonus extra,
when the wood is broken or burned in used.
3. Control panel : 1.500 grill/day × 1 = 1.500 control panel/day
4. Top support : 1.500 grill/day × 2 = 3.000 top support/day
5. Bottom Support : 1.500 grill/day × 2 = 3.000 bottom support/day
6. Tube plugs : 1.500 grill/day × 4 = 6.000 tube plugs/day
7. Knob : 1.500 grill/day × 1 = 1.500 knob/day
8. Leg extensions : 1.500 grill/day × 2 = 3.000 leg extensions/day
9. Tank holder : 1.500 grill/day × 1 = 1.500 tank holder/day
10. Axle : 1.500 grill/day × 1 = 1.500 axle/day
Table III.2 Operation Scrap Rates – courtesy of Moryl GmbH

Operation Name Percent of scrap
Cutting 1% + 1 parts need
Drilling 0,25%
Shearing 0,5 %
Stamping 0,25%
Bending -
Welding -
Deburring 0,5 %
Sanding 0,5 %
Painting -
Assembling -
Inspecting -
Packaging -
Trimming 0,1%
Molding 1%
From Table III.2 we can calculate scraps for each part that will be produce in our
factory, as calculated follow (see the results at Table III.3).
1. Legs→ Cutting: (6.000 × 1%) + 1 = 61
Drilling: 6.000 × 0,25% = 15
Bending: 6.000 × 0% =0
Deburring: 6.000 × 0,5% = 30
Welding: 6.000 × 0% =0
Painting: 6.000 × 0% =0
____________________________________+
Total scrap = 106
Parts needed/day = 6.106
Rezza Prayogi 3-5

2. Wood slats → Cutting: (7.500 × 1%) + 1 = 76

Drilling: 7.500 × 0,25% = 18,75
Sanding: 7.500 × 0,5% = 37,5
____________________________________+
Total scrap = 132,25 ~ 133 round up
3. Control Panel → Shearing: 1.500 × 0,5% = 7,5

Stamping: 1.500 × 0,25% = 3,75
Bending: 1.500 × 0 % = 0
Deburring: 1.500 × 0,5% = 7,5
__________________________________+
4. Top support → Shearing: 3.000 × 0,5% = 15

Stamping: 3.000 × 0,25% = 7,5
Bending: 3.000 × 0 % =0
___________________________________+
5. Bottom support → Shearing: 3.000 × 0,5% = 15

Stamping: 3.000 × 0,25% = 7,5
Bending: 3.000 × 0 % =0
Drilling: 3.000 × 0,25% = 7,5
___________________________________+
Total scrap = 30 + 1 for safety = 31
6. Tube plugs → Molding: 6.000 × 1% = 60

7. Knob → Molding: 1.500 × 1% = 15

8. Leg extensions → Molding: 3.000 × 1% = 30

9. Tank holder → Shearing: 1.500 × 0,5% = 7,5

Stamping: 1.500 × 0,25% = 3,75
Bending: 1.500 × 0% =0
Drilling: 1.500 × 0,25% = 3,75
______________________________________+
Total scrap = 15 + 1 for safety = 16
10. Axle → Cutting: (1.500 × 1%) + 1 = 16

Rezza Prayogi 3-6

Table III.3 Scrap Rates

Part No. Part Name Quantity/ Operations Calculated Parts/
day Needed Scrap Day
Cutting
Drilling
Bending
STG4 Legs 6.000 106 6.106
Deburring
Welding
Painting
Cutting
STG7 Wood slats 7.500 Drilling 133 7.633
Sanding
Shearing
Stamping
STG12 Control Panel 1.500 19 1.519
Bending
Deburring
Shearing
STG8 Top support 3.000 Stamping 23 3.023
Bending
Shearing
Stamping
STG9 Bottom support 3.000 31 3.031
Bending
Drilling
STG5 Tube plugs 6.000 Molding 60 6060
STG13 Knob 1.500 Molding 15 1.515
STG6 Leg extensions 3.000 Molding 30 3.030
Shearing
Stamping
STG10 Tank holder 1.500 16 1.516
Bending
Drilling
STG11 Axle 1.500 Cutting 16 1.516
III.4. Process Design

This sub-chapter will be talking about process design procedures and tools
included route sheets, machine requirements spreadsheets, work cell layouts, work
cell load charts, assembly charts, assembly line balancing forms, and so on.
Every fabricated (manufactured) part requires a completed route sheet. To
complete these route sheets, the industrial engineering department at Moryl GmbH
has been provided time study data, including standard time for operation. The
manufacturing and process engineers at Moryl GmbH provide data regarding the
specific processes so I can choose types of equipment needed. The machine
requirements spreadsheet summarizes fabrication equipment requirements. With the
aid of the assembly chart, assembly lines are identified and balanced to maximize line
efficiency and meet the required takt time or R value.
III.4.1. Cycle Time and Fraction Equipment

The First is calculation of cycle time, fraction equipment, piece/hours,
hour/pieces; this should be used time standard as their base, and this time standard
Rezza Prayogi 3-7

come from time study conduct by Industrial Engineering, using method like
stopwatch time study, work sampling, predetermined time standard system, standard
data, expert opinion based on standard and historical data. But this time I don’t have a
team to conduct this statistical time study, so I use Expert Opinion (assumption) from
Industrial Engineering team at Moryl GmbH. Cycle time is the time standard set by
combining elements of works together into jobs.
1. Axle
a. Cutting
i. Cycle time = 0,165 min/piece
ii. Fraction equipment = cycle time ÷ takt time = 0,165÷0,645 =
0,256
iii. Pieces/hour = 60 min/hour ÷ 0,165 min/pieces = 363,64
iv. Hours/piece = 1÷ 363,64 pieces/hour = 0,00275
v. Hours/1000 = 1000 × 0,00275 = 2,75
2. Tube Plugs
a. Molding
ii. Fraction equipment = 0,0625min/piece ÷ 0,645min/grill= 0,097
iii. Pieces/hour = 60 min/hour ÷ 0,00625 min/piece = 960
iv. Hours/piece = 1 ÷ 960 pieces/hour = 0,00104
v. Hours/1000 = 1000 × 0,00104 = 1,042
b. Trimming
ii. Fraction equipment = 0,073min/piece ÷ 0,645 min/grill = 0,113
iii. Pieces/hour = 60 min/hour ÷ 0,073 min/piece = 832,918
iv. Hours/piece = 1 ÷ 832,918 pieces/hour = 0,00122
v. Hours/1000 = 1000 × 0,00122 = 1,217
3. Leg Extensions
a. Molding
ii. Fraction equipment = 0,125min/piece ÷ 0,645 min/grill= 0,194
v. Hours/1000 = 1000 × 0,00208 = 2,08
b. Trimming
v. Hours/1000 = 1000 × 0,0007 = 0,7
4. Top Support
a. Shearing
Rezza Prayogi 3-8

v. Hours/1000 = 1000 × 0,00055 = 0,55

b. Stamping
v. Hours/1000 = 1000 × 0,00055 = 0,55
c. Bending
v. Hours/1000 = 1000 × 0,00055 = 0,55
d. Painting
i. Cycle time = 60 min/piece
ii. Fraction equipment = 60min/piece ÷ 0,645 min/grill = 93,023
iii. Pieces/hour = 60 min/hour ÷ 60min/piece = 1
iv. Hours/piece = 1 ÷ 1 pieces/hour = 1
v. Hours/1000 = 1000 × 1 = 1000
5. Bottom Support
a. Shearing
v. Hours/1000 = 1000 × 0,00055 = 0,55
b. Stamping
iii. Pieces/hours = 60 min/hour ÷ 0,033 min/piece = 1818,182
v. Hours/1000 = 1000 × 0,00055 = 0,55
c. Bending
v. Hours/1000 = 1000 × 0,00055 = 0,55
d. Drilling
iii. Pieces/hour = 60min/hour ÷ 0,246 min/piece = 243,902
v. Hours/1000 = 1000 × 0,0041 = 4,1
e. Painting
iv. Hours/piece = 1 ÷ 1 piece/hour = 1
Rezza Prayogi 3-9

v. Hours/1000 = 1000 × 1 = 1000
6. Wood Slats
a. Cutting
ii. Fraction Equipment = 0,165 min/piece ÷ 0,645min/grill = 0,256
v. Hours/1000 = 1000 × 0,00275 = 2,75
b. Drilling
ii. Fraction Equipment = 0,123min/piece ÷ 0,645 min/grill = 0,191
v. Hours/1000 = 1000 × 0,00205 = 2,05
c. Sanding
v. Hours/1000 = 1000 × 0,00278 = 2,783
7. Tank Holder
a. Shearing
v. Hours/1000 = 1000 × 0,00055 = 0,55
b. Stamping
v. Hours/1000 = 1000 × 0,00055 = 0,55
c. Bending
v. Hours/1000 = 1000 × 0,00055 = 0,55
d. Drilling
iii. Pieces/hour = 60min/hour ÷ 0,246 min/piece = 243,902
v. Hours/1000 = 1000 × 0,0041 = 4,1
Rezza Prayogi 3-10

8. Knob
a. Molding
v. Hours/1000 = 1000 × 0,00208 = 2,08
b. Trimming
ii. Fraction Equipment = 0,06 min/piece ÷ 0,645 min/grill = 0,093
iv. Hours/piece = 1 ÷ 1000 = 0,001
v. Hours/1000 = 1000 × 0,001 = 1
9. Legs
a. Cutting
v. Hours/1000 = 1000 × 0,00055 = 0,55
b. Drilling
v. Hours/1000 = 1000 × 0,00205 = 2,05
c. Bending
v. Hours/1000 = 1000 × 0,00278 = 2,783
d. Deburring
v. Hours/1000 = 1000 × 0,00208 = 2,08
e. Welding
v. Hours/1000 = 1000 × 8,333
f. Painting
Rezza Prayogi 3-11

v. Hours/1000 = 1000 × 1 = 1000
10. Control Panel

a. Shearing
v. Hours/1000 = 1000 × 0,00055 = 0,55
b. Stamping
v. Hours/1000 = 1000 × 0,00165 = 1,65
c. Bending
v. Hours/1000 = 1000 × 0,00165 = 1,65
d. Deburring
v. Hours/1000 = 1000 × 0,00208 = 2,08
e. Painting
v. Hours/1000 = 1000 × 1 = 1000
The result of above calculation is presented in following route sheet table, including
cycle time, fraction equipment, pieces/hour, hours/piece, hours/1000.
Rezza Prayogi 3-12

Table III.4 Routing sheet for Axle

No.
STG11 Axle DWG11

5 Cutting Big 800 B800 0,165 0,256 363,64 0,00275 2,75
Saw
Table III.5 Routing sheet for Tube Plugs

No.
STG5 Tube Plugs DWG5

NS60
65 Trimming Ergonomic ERGCT 0,073 0,113 832,918 0,00122 1,217
Cutters
Table III.6 Routing sheet for Leg Extensions

No.
STG6 Leg DWG6
Extensions

NS60
65 Trimming Ergonomic ERGCT 0,042 0,065 1428,571 0,0007 0,7
Cutters
Table III.7 Routing sheet for Top Support

No.
STG8 Top DWG8
Support

15 Shearing MINSTER MNS300 0,033 0,051 1818,182 0,00055 0,55
300 Ton
20 Stamping MINSTER MNS300 0,033 0,051 1818,182 0,00055 0,55
300 Ton
25 Bending MINSTER MNS300 0,033 0,051 1818,182 0,00055 0,55
300 Ton
45 Painting IR800 IR800 60 93,023 1 1 1000
Rezza Prayogi 3-13

Table III.8 Routing sheet for Bottom Support

No.
STG9 Bottom DWG9
Support

300 Ton
300 Ton
300 Ton
10 Drilling E2 E2 0,246 0,381 243,902 0,0041 4,1
45 Painting IR800 IR800 60 93,023 1 1 1000
Table III.9 Routing sheet for Wood Slats

No.
STG7 Wood Slats DWG7

5 Cutting Big 800 B800 0,165 0,256 363,636 0,00275 2,75
Saw
10 Drilling E2 E2 0,123 0,191 487,805 0,00205 2,05
40 Sanding Ryobi RBS 0,167 0,259 359,281 0,00278 2,783
Drum
Sender
Table III.10 Routing sheet for Tank Holder

No.
STG10 Tank DWG10
Holder

300 Ton
300 Ton
300 Ton
10 Drilling E2 E2 0,246 0,381 243,902 0,0041 4,1
Rezza Prayogi 3-14

Table III.11 Routing sheet for Knob

No.
STG13 Knob DWG13

NS60
65 Trimming Ergonomic ERGCT 0,060 0,093 1000 0,001 1
Cutters
Table III.12 Routing sheet for Legs

No.
STG4 Legs DWG4

5 Cutting Big 800 B800 0,033 0,051 1818,182 0,00055 0,55
Saw
10 Drilling E2 E2 0,123 0,191 487,805 0,00205 2,05
300 Ton
35 Deburring Handheld IR525 0,125 0,194 480 0,00208 2,083
Grinder
30 Welding Lincoln LR560 0,5 0,775 120 0,00833 8,333
Resistance
45 Painting IR800 IR800 60 93,023 1 1 1000
Table III.13 Routing sheet for Control Panel

No.
STG12 Control DWG12
Panel

300 Ton
300 Ton
300 Ton
35 Deburring Handheld IR525 0,125 0,194 480 0,00208 2,083
Grinder
45 Painting IR800 IR800 60 93,023 1 1 1000
After finish with routing sheet, I calculate the total of machine requirement using
fraction of each routing sheet.
Rezza Prayogi 3-15

Table III.14 Fraction Equipment Spreadsheet

Parts/ Legs Tube Leg Wood Top Bottom Tank Axle Control Knob Rnd
Totals
Equipment STG4 Plugs Ext. Slats Support Support Holder STG11 Panel STG13 Totals
Name STG5 STG6 STG7 STG8 STG9 STG10 STG12
Wood - - - 0,256 - - - - - - 0,256 1
Saw
Metal Saw 0,051 - - - - - - 0,256 - - 0,307 1
Shearing - - - - 0,051 0,051 0,051 - 0,051 - 0,204 1
Stamping - - - - 0,051 0,051 0,051 - 0,153 - 0,306 1
Bending 0,259 - - - 0,051 0,051 0,051 - 0,153 - 0,565 1
Deburr 0,194 - - - - - - - 0,194 - 0,388 1
Sanding - - - 0,259 - - - - - - 0,259 1
Painting 93,020 - - - 93,023 93,023 - - 93,023 - 372,092 373
Trimming - 0,113 0,065 - - - - - - 0,093 0,271 1
Molding - 0,097 0,194 - - - - - - 0,194 0,485 1
Drilling 0,191 - - 0,191 - 0,246 0,381 - - - 1,009 1
Welding 0,775 - - - - - - - - - 0,775 1
Table III.15 Equipment Used

Quantity Equipment Name Operation Machine No. Operation No.
1 Big 800 Saw Cutting wood B800 5
1 Big 800 Saw Cutting steel B800 5
1 MINSTER 300 Ton Shearing, stamping MNS300 15, 20
1 IR800 Painting (booth) IR800 45
IR525 Handheld
3 Deburring IR525 35
Grinder
10 Ergonomic Cutters Trimming plastic ERGCT 65
1 Jutec 850 Bending JTC850 25
1 NISSEI NS60 Injection Molding NS60 75
2 E2 Drilling E2 10
1 Ryobi Drum Sander Sanding RBS 40
Vacuuming
1 BPS2 J69 80
(bagger)
III.4.2. Assembly Chart and Packaging Line

In this sub-chapter, I will present my assembly chart and packaging line
layout. Assembly chart was made based on Figure III.3 (exploded view of my gas
grill). Line balance of packaging department; cycle time made based on time standard
from expert opinion by Industrial Engineering at Moryl GmbH.
Rezza Prayogi 3-16

Grill Legs (2)
Spot Weld
SA1
Side Support (1) (×2)
Paint
P1 Paint
Control Panel (1)

SA2
Bottom Support (2)
SA3
Paint
P2 Paint
Paint
P3 Paint
Tank Holder (1)

SA4
Wood Slats (4)

SA5
Casting
Ignitor
Purchase Parts
Grates SA6
Gas Valving
Burner
Feet & Knob

Fasteners
Bagging
Instructions SA7
Poly Bag
Cardboard Box
Staples
P.O
Cardboard Packing
Figure III.4 Assembly Chart
Rezza Prayogi 3-17

Figure III.5 Packaging Line Layout
Rezza Prayogi 3-18

Line Balance Efficiency of Packaging Department (calculation):

1. Place retainer on conveyor/grill on retainer
a. Cycle Time = 0,327 min/piece
b. Line Time = 0,335 min/piece (based on busiest operation no.9)
c. No. of Station = 0,327 min/piece ÷ 0,645 min/unit = 0,507 station
d. No. of Station round up= 1 station
e. Avg. Cycle Time = 0,327 min/piece ÷ 1 station = 0,327 min/piece
f. % Load = 0,327 min/piece ÷ 0,335 min/piece × 100% = 97,6 %
g. Hours/1000 = 0,335 min/piece ÷ 60 min × 1 station × 1000 = 5,5833
h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1
2. Put manifold & grate in grill
b. Line Time = 0,335 min/piece
d. No. of Station round up = 1 station
f. % Load = 0,304 min/piece ÷ 0,335 min/piece × 100% = 90,7%
h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1
3. Put accessories
h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1
4. Visually inspect, then close lid
h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1
5. Lay legs around grill
f. % Load = 0,221 min/piece ÷ 0,335 min/piece × 100% = 66%
h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1
6. Insert control panel/bottom support and tank control
Rezza Prayogi 3-19


h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1
7. Insert wheel & axle/gas hose
h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1
8. Visually inspect & wrap cardboard retainer
b. Line Time = 0,335 min/piece × 2 = 0,67 min/piece
h. Pieces/hour = 1 ÷ (11,1667/1000) = 89,552
9. Tape box & put on conveyor
f. % Load = 0,335 min/piece ÷ 0,335 min/piece × 100% = 100%
h. Pieces/hour = 1 ÷ (5,5833/1000) = 179,1
10. Push grill assembly in box, insert literature, seal box, date, & place on pallet
b. Line Time = 0,335 min/piece × 2 = 0,67 min/piece
h. Pieces/hour = 1 ÷ (11,1667/1000) = 89,552
Notes for line balance calculation:

 I use plant rate 0,645 min/unit (see calculation for plant rate)
 For line time I use 0,335 min/piece (Avg. Cycle Time operation no 9) for each
workstation, if 2 station needed then the line time will be 0,335 × 2 = 0,667
min/piece.
 Round up for station if more than 0,6 we use round up 2, if bellow 0,6 we use
round up 1
Rezza Prayogi 3-20

 For percent load, I use operation no 9 as my base because it is the biggest

average cycle time (0,335), this is the busiest operation with 100% load.
Table III.16 Line Balance Efficiency of Packaging Department

Oper Operation Cycle Line No. of No. of Avg. % Pcs./Hr. Hrs./1000
ation Description Time Time Stat. Stat Cycle Load
Time
Place retainer on
1 conveyor/grill on 0,327 0,335 0,507 1 0,327 97,6 179,100 5,5833
retainer
Put manifold &
2 0,304 0,335 0,471 1 0,304 90,7 179,100 5,5833
grate in grill
3 Put accessories 0,293 0,335 0,454 1 0,293 87,5 179,100 5,5833
Visually inspect,
4 0,275 0,335 0,426 1 0,275 82,1 179,100 5,5833
then close lid
Lay legs around
5 0,221 0,335 0,343 1 0,221 66,0 179,100 5,5833
grill
Insert control
panel/bottom
6 0,334 0,335 0,518 1 0,334 99,7 179,100 5,5833
support and tank
control
Insert wheel &
7 0,234 0,335 0,363 1 0,234 69,9 179,100 5,5833
axle/gas hose
Visually inspect
8 & wrap cardboard 0,430 0,670 0,667 2 0,215 64,2 89,552 11,1667
retainer
Tape box & put
9 0,335 0,335 0,519 1 0,335 100 179,100 5,5833
on conveyor
Push grill
assembly in box,
10 insert literature, 0,608 0,670 0,943 2 0,304 90,7 89,552 11,1667
seal box, date, &
place on pallet
Total Cycle Time = 3,3614 min/piece

Line efficiency =
Total Cycle Time ÷ (Total Station × Biggest Average Cycle Time) ×100% =
3,3614 min/piece ÷ (12 station × 0,335 min/piece) ×100% = 83,606%
Notes:
 Two picking lines will be running per shift
 Takt time is 0,645 minute per unit, with line efficiency of 83,6%.
Rezza Prayogi 3-21

III.4.3 Flow Analysis Technique
In this sub-chapter I will use Flow Analysis Technique as qualitative and

quantitative tools to design and assess the efficiency of material flow and handling
throughout the facility. As with the route sheet, each fabricated part requires process
chart which, in addition to value-added process, also identifies non-value-added
activities such as storage, delays, material handling, and so on. Process Chart is a
valuable tool in assessing non-value-added steps such as excessive material handling,
delays, and buildup of work in process (WIP), and helps reduce waste and improve
efficiency.
The following process charts to identify various costs associated with material
handling and other inefficiencies. The form-to chart quantifies the efficiency of the
layout resulting from various material movements.
Process Chart Summary Total

Part Name : Axle Operation 2
Transport 3
Inspects 1
Delays 3
Plant : Gas Grill Stores 2
Recorded by : Rezza Prayogi Steps 11
Date : 13 October 2007 Distance 129,54 m
Operation
Transport
Storage
Inspect
Step #
Delay
Description of Hrs./
Method Method Distance Qty. Mvd. Unit Cost/Unit
1 Receive Fork
2267,962 kg 0,5 $5,7
truck
2 Delay for
Inspection
3 Inspection Visual 0,03
$0,38
33
4 Delay for
transportation
5 Transport to Fork
22,86 m 2267,962 kg $0,95
storage truck
6 Storage $0,95
7 Transport to Fork
30,48 m 2267,962 kg
fabrication truck
8 Cut to length B800 0,00
$0,03
275
9 Delay until bin
full
10 Transport to Fork 0,08
76,2 m 1.500 pcs $0,95
packout truck 33
11 Store at packout Fork
1.500 pcs
truck
Rezza Prayogi 3-22


Part Name : Tank Holder Operation 4
Transport 3
Inspects 1
Delays 3
Operation
Transport
Storage
Inspect
Step #
Delay
1 Receive steel Fork
1 0,5 $5,7
coil truck
2 Delay for
Inspection
$3,8
33
4 Delay
5 Move to Fork 0,08
22,86 m 1 $0,95
warehouse truck 33
6 Store
7 Move to Fork 0,08
30,48 m 1 $0,95
fabrication truck 33
8 Shear 0,00
$0,01
055
9 Stamp 0,00
$0,01
055
10 Bend 0,00
$0,01
055
11 Delay until bin
full
15,24 m 1.500 $0,05
drill truck 41
13 Drill E2 0,00
$0,03
278
14 Move to Fork 0,08
76,2 m 1.500 pcs $0,95
packaging truck 33
15 Store at packout
Notes: For distance I use ft to m conversion:

 50 ft = 15,24 m
 75 ft = 22,86 m
 100 ft = 30,48 m
 250 ft = 76,2 m
Rezza Prayogi 3-23


Part Name : Bottom Support Operation 6
Transport 5
Inspects 1
Delays 4
Operation
Transport
Storage
Inspect
Step #
Delay
1 0,5 $5,7
coil truck
2 Delay for
Inspection
$0,38
33
4 Delay for
transportation
22,86 m 1 $0,95
storage truck 33
6 Storage
30,48 m 1 $0,95
8 Shear 0,00
$0,01
055
9 Stamp 0,00
$0,01
055
10 Bend 0,00
$0,01
055
11 Delay until bin
full
15,24 m 1.500 $0,05
drill truck 41
13 Drill E2 0,00
$0,03
278
14 Delay until bin
full
15 Transport to Fork
22,86 m 1.500
paint truck
16 Paint IR800 1 $11,4
15,24 m 1.500 $0,95
packout truck 33
18 Store at packout
Rezza Prayogi 3-24


Part Name : Top Support Operation 6
Transport 5
Inspects 1
Delays 3
Operation
Transport
Storage
Inspect
Step #
Delay
1 0,5 $5,7
coil truck
2 Delay for
Inspection
$0,38
33
22,86 m 1 $0,95
storage truck 33
5 Storage
30,48 m 1 $0,95
7 Shear 0,00
$0,01
055
8 Stamp 0,00
$0,01
055
9 Bend 0,00
$0,01
055
10 Delay until bin
full
7,62 m 1.500 $0,95
weld truck 33
12 Weld LR560
13 Delay until bin
full
22,86 m 1.500 $0,95
paint truck 33
15 Paint IR800 1 $11,4
15,24 m 1.500
packout truck 33
17 Store at packout
Rezza Prayogi 3-25


Part Name : Packaged Grill Operation 46
Transport 10
Inspects 2
Delays 0
Operation
Transport
Storage
Inspect
Step #
Delay
Qty.
Description of Method Method Distance Mvd.
1 Grasp retainer Hand 1
2 Prepare retainer Hand 1
3 Place retainer on Hand
1
conveyor
4 Grasp grill bottom Hand
5 Place grill bottom on Hand
retainer
6 Retainer moves to next Conveyor 1,8288 m
1
operator = 6ft
7 Grasp manifold Hand
8 Place manifold in grill Hand
bottom
9 Grasp griddle Hand
10 Place griddle in grill Hand
bottom
11 Grasp heat shield Hand
12 Place heat shield in Hand
grill bottom
1
operator = 6ft
14 Grasp fastener kit Hand
15 Place fastener kit in Hand
grill bottom
16 Grasp wood slats Hand
17 Place wood slats in Hand
grill bottom
18 Grasp plastic Hand
component kit
19 Place plastic kit in grill Hand
bottom
1
operator = 6ft
21 Perform inspection Visual
22 Grasp grill top Hand
Rezza Prayogi 3-26

23 Place grill top on grill Hand

bottom
1
operator = 6ft
25 Grasp leg assemblies Hand
26 Place leg assemblies on Hand
grill bottom
1
operator = 6ft
28 Grasp bottom support Hand
29 Insert bottom support Hand
30 Grasp control panel Hand
31 Insert control panel Hand
32 Grasp tank holder Hand
33 Insert tank holder Hand
1
operator = 6ft
35 Grasp axle and wheels Hand
36 Insert axle and wheels Hand
37 Grasp gas hose Hand
38 Insert gas hose Hand
1
operator = 6ft
40 Perform inspection Visual
41 Wrap up retainer Hand
42 Tape retainer together Hand
1
operator = 6ft
44 Grasp box Hand
45 Fold box Hand
46 Tape bottom of box Hand
47 Place box on conveyor Hand
1
operator = 6ft
49 Push retainer assembly Hand
into box
50 Grasp literature packet Hand
51 Insert literature packet Hand
into box
52 Box moves to next Conveyor 1,8288 m
1
operator = 6ft
53 Close box Hand
54 Tape top of closed box Hand
55 Grasp time stamper Hand
56 Stamp box with date Hand
57 Grasp box Hand
58 Place box on pallet Hand
Rezza Prayogi 3-27

Flow Process Chart – Axle (STG11)
Receiving
Delay for Inspection
Inspection
Delay for Transport
Transport to Storage
Storage
Transport to Fab
Cut to Length
Delay until Bin Full
Transport to Packout
Store at Packout
Rezza Prayogi 3-28

Flow Process Chart – Bottom Support (STG9)
Receiving
Inspection
Delay for Transport
Storage
Transport to Fab
Shear
Stamp
Bend
To Drill
Drill

To Paint
Paint
Store at Packout
Rezza Prayogi 3-29

Flow Process Chart – Top Support (STG8)
Receiving
Inspection
Delay for Transport
Storage
Transport to Fab
Shear
Stamp
Bend
To Weld
Weld
To Paint
Paint
Store at Packout
Rezza Prayogi 3-30

Flow Process Chart – Control Panel (STG12)
Receiving
Inspection
Delay for Transport
Storage
Transport to Fab
Shear
Stamp
Bend
To Debur
Debur

To Paint
Paint
Store at Packout
Rezza Prayogi 3-31

Flow Process Chart – Knob (STG13)
Receiving
Inspection
Delay for Transport
Storage
Transport to Fab
Mold Part
Trim Part
Delay until bin Full
Store at Packout
Rezza Prayogi 3-32

Flow Process Chart – Leg Extensions (STG6)
Receiving
Inspection
Delay for Transport
Storage
Transport to Fab
Mold Part
Trim Part
Store at Packout
Rezza Prayogi 3-33

Flow Process Chart – Tube Plugs (STG5)
Receiving
Inspection
Delay for Transport
Storage
Transport to Fab
Mold Part
Trim Part
Store at Packout
Rezza Prayogi 3-34

Flow Process Chart – Wood Slats (STG7)
Receiving
Inspection
Delay for Transport
Storage
Transport to Fab
Cut
Transport to Drill
Drill
Transport to Sanding
Sand
Store at Packout
Rezza Prayogi 3-35

Flow Process Chart – Tank Holder (STG10)
Receiving
Inspection
Delay for Transport
Storage
Transport to Fab
Shear
Stamp
Bend
To Drill
Drill
Store at Packout
Rezza Prayogi 3-36

Flow Process Chart – Legs (STG4)
Receiving
Inspection
Delay for Transport

Storage
Transport to Fab
Cut
Transport to Drill
Drill
Transport to Debur
Debur
Transport to
Welding
Weld
Transport to Paint
Paint
Store at Packout
Rezza Prayogi 3-37

Table III. 17 Routing for ten parts

Part Name Part No. Routing (Operation Sequence) Weight
Axle STG11 RM → C → S 1
Bottom Support STG9 RM → ST → B → D → S 4
Control Panel STG12 RM → ST → B → DB → S 4
Knob STG13 RM → M → S 1
Legs STG4 RM → C → D → B → DB → W → S 5
Leg extensions STG6 RM → M → S 1
Wood slats STG7 RM → C → D → DB → S 2
Tank holder STG10 RM → ST → B → D → S 2
Top support STG8 RM → ST → B → W → S 4
Tube plugs STG5 RM → M → S 1
Notes:
 RM = Raw Material  D = Drilling
 ST = Stamping  M = Injection Molding
 DB = Deburring  W = Welding
 B = Bending  S = Storage
 C = Cutting
From-To-Chart
Deburring
To
Stamping
Injection
Molding
Welding
Bending
material
Drilling
Storage
Cutting
Penalty
Point
Total
Raw
From
Raw 4,4,2,4 1,5,2 1,1,1
25 67
material 14 32 21
Stamping 4,4,2,4
14 14
14
Bending 4,2 4,5 4
6 27 16 19 49
Drilling 5 2 4,2
10 4 30 13 44
Cutting 5,2 1
14 4 8 18
Deburring 5 4,2
5 18 11 23
Welding 4,5
18 9 18
Injection 1,1,1
3 3 3
Molding
Storage
102 236
From-to-chart calculation:
 Penalty point (horizontal direction):
o From Raw material to Stamping = 1 × (4+4+2+4) = 14
o From Raw material to Cutting = 4 × (1+5+2) = 32
Rezza Prayogi 3-38

o From Raw material to Injection Mold = 7 × (1+1+1) = 21

o From Stamping to Bending = 1 × (4+4+2+4) = 14
o From Bending to Drilling = 1 × (4+2) = 6
o From Bending to Deburring = 3 × (4+5) = 27
o From Bending to Welding = 4 × (4) = 16
o From Drilling to Deburring = 2 × (2) = 4
o From Drilling to Storage = 5 × (4+2) = 30
o From Cutting to Storage = 4 × (1) = 4
o From Deburring to Welding = 1 × (5) = 5
o From Deburring to Storage = 3 × (4+2) = 18
o From Welding to Storage = 2 × (4+5) = 18
o From Injection Mold to Storage = 1 × (1+1+1) = 3
 Penalty point (vertical direction):
o From Drilling to Bending = 2 × (5) = 10
o From Cutting to Drilling = 2 × (5+2) = 14
 Efficiency:
o Efficiency = (Total Weighting ÷ Total Penalty Point) × 100% = 102 ÷
236 × 100% = 43,22%
Rezza Prayogi 3-39

III.4.4 Activity Relationship Analysis
This sub-chapter will discuss the four techniques for establishing optimal
material flow in a manufacturing facility: the activity relationship diagram, the
worksheet, the dimensionless block diagram, and the flow analysis.
This segment employs the four techniques to determine the most efficient
layout possible for my gas grill project. The activity relationship diagram and
worksheet show the relationships among the various activities and operation
performed in the facility. From that information, a dimensionless block diagram is
created showing a proposed layout. Additional flow analysis studies are conducted to
better understand the limitation of the design by identifying congested and bottleneck
areas. These visual aids can lead the improvement in the design.
Activity Relationship Diagram

1
Fabrication 2
1
A 3
Painting
2 O 4
O I 5
Shipping
3 O I 6
U O U 7
Receiving
4 A E E 8 8
A E O I 9
Warehouse/
5 U U I X 10
Stores A U O X O 11
Packaging
6 U U O C X I 12
I O O U O I
Maintenance
7 E U U C O U 1
I U U U U 2
Quality Control
8 O U U U U 3
O O O O 4
Offices
9 U E U O 5
E O I 6
Cafeteria
10 U I U 7
U O 8
Tool Room 9
11 E
O 10
Locker Room
12 11
12
Notes:
A = Absolutely necessary that these tow departments be next to each other
E = Especially important
I = Important
O = Ordinary importance
U = Unimportant
X = Closeness undesirable
Rezza Prayogi 3-40

Table III.18 Activity Relationship Worksheet

Department A E I O U X
1 Fabrication 2 7 4,5,8,11,12 3,10 6 9
2 Painting - 6 8 3,4,5,7,11 12 9,10
3 Shipping 5 6 - 1,2,8,9,11 4,7,10,12 -
4 Receiving 5 - 1 2,9 3,6,7,8,10,11,12 -
5 Warehouse 3,4,6 - 1 2,8,12 7,9,10,11 -
6 Packaging 5 2,3,8 7 11,12 1,9,10 -
7 Maintenance - 1,11 6,8,12 2,9,10 3,4,5 -
8 Quality Control - 6 1,2,7,12 3,5,9,11 4,10 -
9 Offices - 10 - 3,4,7,8,12 5,6,11 -
10 Cafeteria - 9,12 - 1,7 3,4,5,6,8,11 -
11 Tool Room - 7 1 2,3,6,8,12 4,5,9,10 -
12 Locker Room - 10 1,7,8 5,6,9,11 2,3,4 -
Notes:
A = Absolutely necessary that these tow departments be next to each other
E = Especially important
I = Important
O = Ordinary importance
U = Unimportant
X = Closeness undesirable
- 1,11 - 7 - 6
7 11 8
Maintenance Tool Room Quality Control
6,8,12 2,9,10 1 2,3,6,8,12 1,2,7,12 3,5,9,11

2 7 1 6 5 3,4,8
1 2 6
Fabrication Painting Packaging
9,10
9
4,5,8,11,12 3,10 8 3,4,5,7,1 7 11,12
5 - 3,4,6 - 5 6
4 5 3
Receiving Warehouse/Stores Shipping
- 2,9 1 2,8,12 - 1,2,8,9,11

- 10 - 9,12 - 10
9 10 12
Offices Cafeteria Locker Room
- 3,4,7,8,12 - 1,7 1,7,8 5,6,9,11
Figure III.6 Dimensionless Block Diagram
Rezza Prayogi 3-41

Figure III.7 Flow Diagram for Axle
Rezza Prayogi 3-42

Figure III.8 Flow Diagram for Tank Holder
Rezza Prayogi 3-43

Figure III.9 Flow Diagram for Bottom Support
Rezza Prayogi 3-44

Figure III.10 Flow Diagram for Top Support
Rezza Prayogi 3-45

Figure III.11 Flow Diagram for Control Panel
Rezza Prayogi 3-46

Figure III.12 Flow Diagram for Knob, Leg Extensions and Tube Plug
Rezza Prayogi 3-47

Figure III.13 Flow Diagram for Wood Slats
Rezza Prayogi 3-48

Figure III.14 Flow Diagram for Legs
Rezza Prayogi 3-49

III.5. Equipment and Space Used

Four preceding sub-chapters dealt with various aspects of space needs
assessment and calculations. From space for personal to equipment space
requirements, all area allocations for Gas Grill Factory are summarized and presented
here.
The following figures include layout data for machinery and equipment and
equipment space, total spaces and office space requirements for the Gas Grill Factory
plant. Keep in mind that overall size of the facility is the sum of all individual units.
Every workstation, department, office area, and activity should be considered and its
space needs must be analyzed and determined. Therefore, a completed project will
have a layout for every work center, office space, and all raw, WIP, and finished
inventory. If you do not consider the space needs for a particular inventory item
(rework and scrap, too), or where to park material handling equipment, or where to
store your pallets, you can rest assured that these items will overflow into the aisles or
other undesirable places. This will not only point to lack of foresight on the part of the
facilities planner but it will also create an unsafe and congested work environment.
Name/Type: Jutec850/Bender
Manufacturer: Jutec
Electrical : 220V
Machine number: JTC850
Gross Area Needed 106 ft² = 9,8477 m²
Figure III.15 Bender Equipment Layout
Rezza Prayogi 3-50

Name/Type : Lincoln560/ Resistance Point Welding

Manufacturer : Lincoln
Electrical : 220V
Machine number : LR560
Gross Area Needed : 67 ft² = 6,2245 m²
Figure III.16 Welding Equipment Layout
Name/Type : Radial Saw

Manufacturer : B800 (Delta)
Electrical : 220V
Machine number : B800
Figure III.17 Saw Equipment Layout
Rezza Prayogi 3-51

Name/Type : Drill Press

Manufacturer : Tradesman
Electrical : 220V
Machine number : 8062 Tradesman
Figure III.18 Drill Equipment Layout
Name/Type : Stamp
Manufacturer : Minter 300
Electrical : 220V
Machine number : MNS300
Gross Area Needed 476 ft² = 44,22 m²
Figure III.19 Stamp Equipment
Rezza Prayogi 3-52

Name/Type : Sander
Manufacturer : RYOBI
Electrical : 220V
Machine number : RBS
Figure III.20 Sand Equipment Layout
Name/Type : Poly Bag

Manufacturer : SHARP
Electrical : 220V
Machine number : J69
Figure III.21 Poly Equipment
Rezza Prayogi 3-53

Name/Type : Paint Booth

Manufacturer : Ingersoll Rand
Electrical : 220V
Machine number : IR800
Figure III.22 Paint Equipment Layout
Rezza Prayogi 3-54

Name/Type : Injection Mold

Manufacturer : NISSEI
Electrical : 220V
Machine number : NS60
Figure III.23 Injection Mold Equipment Layout
Rezza Prayogi 3-55

Table III.19 Storage Space Calculation

Part Size(in) in³ Maximum Maximum Average ft³ Shelf Pallets
Quantity Space (in³) Inventory 1×1×3 4×4×4
Bottom
Grill 14 16 24 5.376 1.000 5.376.000 2.880.000 1.557,36 0 23,33
Casting
Top Grill
16 18 10 2.880 1.000 2.880.000 1.440.000 834,30 0 13,04
Casting
Wood
10 2 2 40 1.000 40.000 20.000 11,59 3,86 0
Handle
Wheels 6 6 2 72 2.000 144.000 72.000 41,71 13,9 0
Hub Caps 2 2 2 8 2.000 16.000 8.000 4,63 1,54 0
Ignitor 3 2 2 12 1.000 12.000 6.000 3,48 1,16 0
Valve
10 4 4 160 1.000 160.000 80.000 46,35 15,45 0
Assembly
Burner
12 4 4 192 2.000 384.000 192.000 111,24 37,08 0
Element
Cooking
14 16 0,5 112 1.000 112.000 56.000 32,44 10,81 0
Grid
Rock Grate 14 16 2 448 1.000 448.000 224.000 129,78 0 2,03
Heat Shield 10 6 6 360 1.000 360.000 180.000 104,29 0 1,63
Accessories
10 12 12 1.440 1.000 1.440.000 720.000 417,15 139,05 0
Bag
TOTALS 3.294,32 222,87 41,03
This is PARTIAL listing of parts

Shelving units contain 7 shelves
Total number of shelving units needed: 100
Total aisle feet for shelving unit: 300
Racks can hold 6 pallets (2 high x 3 wide x 1 deep) and measure 15 ft across
Total number of racks needed: 50
Total aisle feet for racks: 750
Table III.20 Equipment Space Requirement

Machine Name Operation Machine code Space Required
JUTEC 850 Bender JTC850 106 ft2 = 9,85 m2
DrillPress Drill 8062 TRADESMAN 34 ft2 = 3,16 m2
Lincoln Resitance Welder LR560 67 ft2 = 6,23 m2
MINTER 300 Stamp MNS300 476 ft2 = 44,22 m2
Big 800 Wood/Steel Saw B800 152 ft2 = 14,12 m2
RYOBI Sander RBS 31 ft2 = 2,88 m2
SHARP Poly Bag J69 64 ft2 = 5,95 m2
Ingersoll Rand Paint Booth IR800 440 ft2 = 40,88 m2
NISSEI Injection Mold NS60 73 ft2 = 6,78 m 2
Parking Space Requirement

Total employees of first shift is 49 (make round-up to 50)
50 × 1,5 = 75 parking spaces
Rezza Prayogi 3-56

Table III.21 Total Space Requirement

Name of the Area Space in ft2 Space in m2
Receiving Department 750 69,68
Raw Material Storage 4,050 0,38
Fabrication Department 6,825 0,63
Paint Department 2,260 0,21
Packaging Department 7,5 0,70
Finished Goods Storage 7,850 0,73
Shipping Department 750 69,68
Offices 4,150 0,39
Maintenance 400 37,16
Tool Room 170 15,79
Quality Control 170 15,79
Locker Room 1,440 0,13
Cafetaria 600 55,74
Total Needed 36,915 3.429,52
Table III.22 Office Space Requirements (Equipment Space)

Position Desk/Chair Table File Side Bookcase # Positions Total Total Space
Cabinet Chair ×2
President 50 ft2 20 ft2 5 ft2 2×8 ft2 3 ft2 1 94 188 ft2
2 2 2 2 2
VP 50 ft 20 ft 5 ft 2×8 ft 3 ft 1 94 188 ft2
2 2 2 2 2
Engineer 40 ft 15 ft 5 ft 8 ft 3 ft 2 71 142 ft2
HR 40 ft2 - 5 ft2 8 ft2 3 ft2 2 56 112 ft2
2 2
Secretary 35 ft - 5 ft - - 2 80 160 ft2
Receptionist 35 ft2 - 5 ft2 - - 1 40 80 ft2
Table III.23 Total Office Size

Position Office Size
President 400 ft2
VP 350 ft2
Engineer 300 ft2
HR 250 ft2
Secretary 100 ft2
Receptionist 100 ft2
III.6. Material Handling Equipment Used

Material handling equipment requirements for my gas grill factory are
summarized in the following figures.
Table III.24 Material Handling Equipment

Type Description Quantity
Pneumatic Tire Rider Yale GP-DA/EA 1
Cushion Tire Rider Yale GC-RG 3
Low Lift Walkie Pallet Yale MPB 2
Roller Bed conveyor Hytrol RB 12 (with different length)
Rezza Prayogi 3-57

GENERAL
Type Pneumatic Tire Rider
Yale model design GP-DA/EA
Capacity range (lb) 16.500 – 36.000
Power Steering Standard
Yale Hi-Vis mast Standard
ENGINE
Gas GM 6.0L V8
Cylinders 8
Figure 11.24 Yale GP-DA/EA Pneumatic I.C.E Lift Truck
Rezza Prayogi 3-58

GENERAL
Type Cushion Tire Rider
Yale model design GC-RG
Capacity range (lb) 4000 – 5000
Power Steering Standard

Yale Hi-Vis mast Standard
ENGINE
Propane Yale FE
Cylinders 4
Figure III.25 Yale GC-RG Cushion I.C.E Lift Truck
Rezza Prayogi 3-59

GENERAL
Type Low Lift Walkie Pallet
Yale model design MPB
Capacity range (lb) 4000
MOTOR
Electric 24 Volt
Figure III.26 Yale MBP Motorized Hand Pallet Truck
Rezza Prayogi 3-60

GENERAL
Type Live Roller Conveyor
Capacity Range (lb) 15 per roller
MOTOR
Drive Center Drive/Reversible
HP ¾ to 2 HP Available
Conveyor Speed
R-Value 0.645 min
Speed (ft/min) 15.5 ft/min
Figure III.27 Hytrol RB Horizontal Bed Conveyor (Roller Bed)
III.7. Cost Calculation
This segment of “Gas Grill Project Calculation” will bring the design of a
manufacturing facility for the production of the Gas Grill to its conclusion. The
following figures show the final layout of the facility. The components of this layout,
various departments and activity centers, their locations and their interrelationships, as
well their size, are based on the project requirements determined and articulated
throughout different stages of the process.
Additional data, such as direct and indirect labor costs, some overhead costs,
and equipment costs are also presented in this concluding sub-chapter. Although
somewhat a cursory approach, an earnest effort has been made to determine the cost
and the suggested price of the final product.
Rezza Prayogi 3-61

Figure III.28 Final facility layout in 2D
Rezza Prayogi 3-62

Table III.25 Salaried Personal Requirement

Position No. of Salary* ($) Total Daily Cost** ($)
Position
President 1 90.000 90.000 450
VP 1 78.000 78.000 390
Engineer 2 54.000 108.000 540
Supervisors 6 48.000 288.000 1.440
HR 1 38.400 38.400 192
*Includes 20% for benefits

**Figured on 200 production days per year
Table III.26 Hourly Personal Requirement

Shift
st
Position 1 2nd 3rd $ per hour* Daily Cost
Material Handler 3 3 3 11,4 820,8
Machine Operator 9 9 9 11,4 2.462,2
Packaging 13 13 13 10,20 3.182,4
Tool and die 1 1 - 18 288
Maintenance 2 2 2 13,2 633,6
Mechanic 1 - - 13,2 105,6
Quality 1 1 1 11,4 273,6
Janitor 2 2 2 11,4 574,2
Warehouse 2 2 2 11,4 574,2
Shipping 2 2 2 11,4 574,2
Receiving 3 3 3 11,4 820,8
Secretarial 3 1 1 11,4 456,6
Total Daily Cost $10.765,60

*Includes 20% for benefits
Table III.27 Employee Requirements

Shift Hourly Salary Total
1 42 7 49
2 39 2 41
3 38 2 40
Total number of this grill factory employees = 49+41+40 = 130
Rezza Prayogi 3-63

Table III.28 Equipment Cost

Qu Equipment Name Operation Machine Cost per Total ($)
anti No. Unit ($)
ty
1 Big 800 Saw Cutting wood B800 400 400
1 Big 800 Saw Cutting steel B800 400 400
1 MINSTER 300 Ton Shearing, stamping MNS300 1.100.000 1.100.000
1 IR 800 Painting IR800 20.000 20.000
3 IR 525 Handheld Deburring IR525 50 150
Grinder
10 Ergonomic Cutters Trimming plastic ERGCT 7,5 75
1 Jutec 850 Bending JTC850 1.200 1.200
1 NISSEI NS60 Injection Molding NS60 30.000 30.000
2 E2 Drilling E2 275 550
1 Ryobi Drum Sander Sanding RBS 350 350
1 BPS2 Vacuum Bagging J69 4.000 4.000
Table III.29 Total Cost for a Grill
Manufacturer’s Cost
Daily Cost ($) Per Unit Cost ($)
Hourly labor cost 10.765,60 7,17
Salaried cost 3.120 2,08
Raw material cost 4.470 2,98
Purchase parts cost - 36,23
Equipment & facilities cost* 5.000 3,33
$51,79
*Based on a 10-year payback of $10, with 200 workdays per year, and 300.000 grills
per year.
The grill will be sold to retailers and distributors for $75 each. The average retail price
for this grill will be approximately $119,95.
Our profit is $23,21/grill, for a total of $6.963.000/year.
As was stated in the introduction to this project, this case study is intended to
merely illustrate a systematic approach to designing a manufacturing facility.
Successful planning also requires creativity and sound judgment.
Rezza Prayogi 3-64

CHAPTER IV
BUILDING DIGITAL FACTORY
IV.1. Delmia Quest

DELMIA QUEST is a complete 3D digital factory environment for process
flow simulation and analysis, accuracy, and profitability. QUEST’s flexible, object-
based, discrete event simulation environment combined with powerful visualization
and robust import/export capabilities makes it the engineering and management
solution of choice for process flow simulation and analysis.
DELMIA QUEST provides a single collaborative environment for industrial
engineers, manufacturing engineers, and management to develop and prove out best
manufacturing flow practices throughout the production design process. Improve
designs, reduce risk and cost, and maximize efficiency digitally, before spending
money on the actual facility, to get it right the first time. By using QUEST to
experiment with parameters such as facility layout, resource allocation, kaizen
practices, and alternate scheduling scenarios, integrated product teams can quantify
the impact of their decisions on production throughput and cost.
IV.2. Experiment
In this sub-chapter, I will present my step by step learning process by doing
experiment simulation using Delmia Quest. This experiment is conduct to become
more expert in this new system. I give a data and picture that I have created a long
with my experiment.
IV.2.1 Single machine

This experiment will show the basic modelling constructs used to develop a
QUEST simulation model. The concepts of a part class and element class are used to
build a simple straight-through processing system.
Table IV.1 Data for single machine:

Source Quantity: 1
Entity Arrival: Exponential (Mean 25 second)
Output type: push
Entity Quantity: 1
Machine Quantity: 1
Cycle Time: Normal (Mean 25 sec, Standard Deviation 5 sec)
Buffer Quantity: 2
Capacity: INF
Input/Output type: Push
Sink Quantity: 1
Input Type: push
Simulation Run: 1000 second
Warm Up: 0 sec
Rezza Prayogi 4-1

Figure IV.1 Layout for simulation with single machine
Figure IV.2 Simulation with single machine
IV.2.2. Three assembly machine

This experiment will show the intermediate modelling constructs used to
develop a QUEST simulation model. The concepts of a part source, sink, buffer, and
machine are expanded and further described. Additional modelling features such as
simple route logic, multiple processes, and part requirements are demonstrated. The
experiment involves building a straight-through processing system using
combinations of multiple sources, buffers, machines, and parts. User-defined names
and alternative model scenarios will be established to illustrate model experimentation
runs.
The system to be modeled in this experiment involves the assembly of three
different types of end products on three available flexible machines. Parts PartA,
PartB, and PartC are assembled with PartD to form end products PartAD, PartBD, and
PartCD, respectively. Machines Mach1, Mach2, and Mach3 require the appropriate
part requirements from dedicated upstream buffers to produce the end products on a
Rezza Prayogi 4-2

cyclic basis. Assembled products are sent from the machines to a common buffer,
after which they exit the system.
Table IV.2 Data for three assembly machine:

Entity Part Quantity: 4 Part (A,B,C,D)
Assembly Quantity: 3 Assy (AD, BD, CD)
SourceABC Quantity: 1
Part Fraction: 3
Output type: push
Route Logic: Fixed Routing (part restrictions)
Interarrival Time: Exponential (mean 15 sec)
SourceD Quantity: 1
Part Fraction: 1
Interarrival Time: Constant (15 sec)
Machine Input: 4 Part (A,B,C,D)
Output: 3 Assy (AD, BD, CD)
Cycle Time: Exponential (mean 40 sec)
Buffer Quantity: 3
Capacity: INF
Input/Output Type: Push
Sink Quantity: 1
Capacity: INF
Input type: push
Simulation Run Time: 1000 sec
Warm Up: 0 sec
Figure IV.3 Layout for simulation with three assembly machine
Rezza Prayogi 4-3

Figure IV.4 Simulation with three assembly machine
IV.2.3. Conveyor system

This experiment will show the basic modelling constructs used in developing a
basic conveyor system in a QUEST simulation model. The concepts of part, source,
sink, buffer, and machine are used in association with different conveyor modelling
constructs. The experiment involves building a conveyor system that services two
parallel workstations.
Table IV.3 Data for conveyor system:

Entity Quantity: 2
Source Quantity: 1
Interarrival Time: Normal (Mean 20 sec, standard deviation 4
sec) Part Fraction: 2
Roller Quantity: 1
Conveyor Input/ Output Type: push Capacity: Infinite (INF)
Conveyor Type: Accumulating
Speed: 0,5 ft/sec
Belt Quantity: 8 (connected each)
Conveyor Arc Radius: 3 ft
Input/ Output Type: push Capacity: Infinite
Conveyor Type: non-accumulating
Speed: 0,5 ft/sec
Decision Point at 1st connection: Process Logic  Unload
Part1, Pass Part 2
Machine Quantity: 2
Cycle Time: Uniform (minimum 5 sec, maximum 15 sec)
Input/ Output Type: push
Buffer Quantity: 3
Capacity: infinite Input/ Output Type: push
Sink Quantity: 2
Input Type: push
Rezza Prayogi 4-4

Simulation Run: 1000 sec

Animation On Step Size: 8 sec Animation Off Step
Size: 480 sec
Figure IV.5 Layout for simulation with conveyor system
Figure IV.6 Simulation with conveyor system
IV.2.4. Power and Free System

This experiment will show the basic modelling constructs used in developing a
Power and Free system. The concepts of Power and Free systems, Segments, Decision
Points and Carriers are showed here.
Rezza Prayogi 4-5

Table IV.4 Data for power and free system:

Entity Quantity: 2
Source Quantity: 1
Part Fraction: 2
Interarrival Time: Exponential (mean 45 sec)
Sink Quantity: 1
Input Type: Push
Buffer Quantity: 1
Input/ Output Type: Push Capacity: Infinite
Power and Quantity: 2 Loop (connected)
Free Speed: 0,3 ft/sec
Segment Dog Spacing: 5 ft Elevation: 10 ft Arc
Radius: 3 ft
Decision Point at Source: Logic  load
Decision Point at Sink: Logic  Unload (claim capacity: 5 at
this point)
Decision Point at connection: Logic  Route by Part
Carrier Quantity: 15
Type: MHS
Stopping space: 5 ft
Locate Direction: Forward
Simulation Runtime: 7200 sec
Figure IV.7 Element in Power and Free System simulation
Figure IV.8 Layout Power and Free with its Decision Point
Rezza Prayogi 4-6

Figure IV.8 Simulation with power and free system
IV.2.5. Labor, Shift, and Downtime

This experiment will show the concepts of labor allocation, shift scheduling,
and downtime modelling in a QUEST simulation model. The concepts part, source,
sink, buffer, and machine are used in association with labor requirements and their
respective shift schedules. The experiment also involves defining equipment
downtime and applying them on selected model elements.
Table IV.5 Data for labor, shift, and downtime:

Entity Quantity: 2
Machine Quantity: 4
Buffer Short Quantity: 4
Capacity: 100.000
Buffer Long Quantity: 2
Capacity: 6
Source Quantity: 2
Part Fraction: 1 each part
IAT : Exponential (mean 75 sec)
Machine Quantity: 4 Input/Output Type: push
Cycle Time : Exponential (mean 20 sec)
Downtime: Exponential (mean 3600 sec) Time to Repair
: Uniform (min 180, max 300)
Sink Quantity: 2 Input Type: push
Labor controller Quantity: 1
Labor Quantity: 2 Speed: 2 ft/sec
Rotation Speed: 360 deg/sec
Rezza Prayogi 4-7

Move Time: constant 10 sec Break1: 15 minutes

Break2: 30 min
No. of Break: 3
Daily Schedule: start 00:00 – end 09:00
Simulation Runtime: 32400 sec (9 hours)
Figure IV.9 Model layout for simulation with Labor
Figure IV.10 Simulation with labor, shift and downtime
Rezza Prayogi 4-8

IV.2.6. Labor I
This experiment introduces the concept of labor allocation in a QUEST
simulation model. In this experiment, the concepts of part, source, sink, buffer, and
machine are used in association with labor requirements.
Table IV.6. Data for Labor I Simulation

Entity Quantity: 2
Machine Quantity: 4
Buffer Short Quantity: 4
Capacity: 100.000
Buffer Long Quantity: 2
Capacity: 6
Source Quantity: 2
Part Fraction: 1 each part
IAT : Exponential (mean 75 sec)
Machine Quantity: 4 Input/Output Type: push
Cycle Time : Exponential (mean 20 sec)
Sink Quantity: 2 Input Type: push
Labor Quantity: 2 Speed: 1 ft/sec
Simulation Runtime: 32400 sec (9 hours)
Figure IV.11 Model Layout for simulation with Labor
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Figure IV.12 Completed Model
IV.2.7. Labor II
This experiment explains another way of modelling the labor in a QUEST
model. It explains the concept of labor movement along "via paths". Labor via paths
are simple straight line paths created between Labor Points of different elements. In
the default method, when the labor is requested to move to an element, a default
straight line via path is created between its current Labor_Pt and the destination
elements selected Labor_Pt. In the user-created method, the user can create labor via
paths between different elements. When it is first created, it is a default straight line
path with a starting and ending via points. Additional via points can be added to the
via path and their positions/orientation can be modified.
Table IV.7. Data for Labor via paths simulation

Entity Quantity: 1
Source Quantity: 1
Interarrival Time: Constant 15 sec
Machines Quantity: 4
Type: Lathe
Cycle Time: constant 15 sec
Buffer Quantity: 1
Sink Quantity: 1
Labor Quantity: 2
Locate labor: on a labor point
Speed: 1 ft/sec
Routing Part Part > Routing Requirement > Any Labor
Routing Machine Machine > Part Routing (type specific) > Labor
Requirement > All Part = Any
Machine > Labor Depart Requirement > Any Part
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Combination 1
Routing Source Source > Part Routing (type specific) > Labor
Requirement > All Part = none
Routing Buffer Buffer > Logics > Route Logic > Cyclic Order
Simulation Runtime: 1000 sec
Figure IV.13 Layout for Labor experiment via paths
Figure IV.14 Simulation Labor via paths
IV.2.8. Labor III

This experiment explains another way of modelling the labor in the QUEST
model. It explains the concept of labor movement on the path system, a little bit
different from previous experiment. Labor movement on a path system is similar to
AGV movement. A labor path system element can be created with the segments and
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labor decision points. The labor moves between the labor decision points through the
segment connections. Labor has no acceleration or deceleration.
Table IV.8. Data for labor movement on path system

Entity Quantity: 1
Source Quantity: 1
Interarrival Time: constant 60 sec
Sink Quantity: 1
Buffer Quantity: 1 Route Logic: Cyclic order
Machine Quantity: 4
Cycle Time: constant 15 sec
Labor Segment Quantity: 1 Direction: Bi Directional Max Speed: 0.3ft/sec
Labor Controller Quantity: 2 (for left path and right path)
Labor Decision Point Quantity: 8
Labor Quantity: 2
Locate labor: on a path system
Animation mode: move between point
Speed: 1 ft/sec
Depart Requirements For labor decision point 1, 2, 3, 5, 6, 7: Any Part =1,
Combination-1
For labor decision point 4, 8: Any Part = all 0, no combination
Part Destination For every decision point, add fixed part destination for part1
From decision point 1 to decision point 2
Simulation Runtime: 7200
Figure IV.15 Layout for simulation labor with path system
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Figure IV.16 Simulation labors with its special path system
IV.2.9. Pallet
This experiment will show how to model pallets (container parts) i.e, parts that
can carry other parts. The model that we will construct in this tutorial will have a
machine Machine1 that takes in two parts Part1, Part2 and a pallet Pallet1. The
machine will pack Part1 and Part2 into Pallet1 and send it on a conveyor. At the end
of the conveyor, another machine Machine2 will unpack Pallet1. The parts will be
sent to a sink and the pallet will go back to Machine1 to be packed with Part1 and
Part2.
A pallet is basically a part in QUEST. To add additional display properties like
stack points to the pallet, a sub-resource class has to be associated to the pallet's part
class. The display attributes of the sub-resource class will then be used by the parts
created as pallets.
Table IV.9. Data for labor movement on path system

Entity Quantity: 2
Sink Quantity:1
Sub-Resource Class Display> No. Stack Point: 2 > 3D display as Plate
Stacking table> Part1 > Stack Pt-1
Stacking table> Part2 > Stack Pt-2
Pallet Part Class Quantity:1
Associated Sub-resource class: sub-Resource1
Source Quantity:1
Part Fraction: part 1=1, part2=1, pallet=0
Buffer1 Quantity:1
Unload Process> Part Pre-requisites: change quantity for Any
Part=0, Pallet=0, Part1=1, Part2=1
Buffer2 Quantity:2
Part Initial Stock: Pallet=5, Part1=0, Part2=0
Cycle Process Name: Packing Process
Part> Quantity> Any Part=0, Part1=1, Part2=1, Pallet=1
Product> Method> Part1 = Pack, Part2 = Pack, Pallet= Pass
Through
Cycle Process Name: Unpacking Process
Part> Quantity> Any Part, Part1, Part2 = 0, Pallet=1
Product> Method> Part1, Part2 = none, Pallet= unpack
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Conveyor Type: Chain long

Conveyor Info> Moving Space: 0,32ft
Packing Machine Quantity:1
Cycle Process: Packing Process
Unpacking Machine Quantity:1
Cycle Process: Unpacking Process
Logic> Route Logic: Fixed Routing
Part Routing> Restriction: Part1 route Output1, Part 2 route
Ouput1, Pallet route Output2
Simulation Runtime: 1000sec
Figure IV.17. Layout for Pallet Simulation
Figure IV.18. Simulation with Pallet
IV.3. Gas Grill Manufacturing Simulation

All data in this sub-chapter simulation are based on calculation Chapter 3, in
this master thesis.
IV.3.1. Axle Production

This simulation is based on Routing Sheet, Process Chart, Flow Diagram for
Axle in Chapter 3 in this master thesis.
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Table IV.10. Data for Axle Part Production

Part Quantity: 1 Name: Axle
Source Quantity: 1, Part Initial Stock: 5
IAT: Exponential mean 0,5 hr/unit
Unload Process> Part Prerequisites> Axle quantity 5
Buffer Quantity: 1
Unload Process> Part Prerequisites> Axle quantity 5
Machine Quantity: 1 Name: SawB800 Type: cutting
Cycle Time: Exponential mean 0,00275 hr/unit
Rejection Rate: 1%
Conveyor Type: Roller Accumulating, Quantity:1
Speed: 15,5 ft/min or 283.464 m/hr
Labor Segment Quantity:3 Direction: Bi Directional Max Speed: 10800m/hr
Labor Controller Quantity:3
for 2 labor as forklift with capacity number: 5 part
Labor Decision Point Quantity: 7 Labor controller depend on its area
Labor Quantity: 3, 1 as human, 1 as forklift, and 1 as hand pallet truck
Depart Requirements For decision point 1,3,5,6: Any Part = 1, Combination-1
For decision point 2,4,7: Any Part = all 0, no Combination
Part Destination For every decision point, add fixed part destination for Axle
Simulation Runtime: 24hr
Labor
Controller3
Sink
Labor
Controller2
Dec_Point6,7
Machine
Dec_Point3,4,5
Dec_Point1,2
Labor
Source
Forklift
Labor
Controller1
Figure IV.19 Layout for Axle production simulation
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Figure IV.20 Step 1 simulation with forklift bring raw material for axle
Figure IV.21 Step 2 simulation with material in cutting machine
Figure IV.22 Step 3 simulation with finished axle going to packout
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IV.3.2. Tank Holder Production

Tank Holder part in Chapter 3 in this master thesis.
Table IV.11. Data for Tank Holder Part Production

Part Quantity: 1 Name: Tank Holder
Unload Process> Part Prerequisites> Tank Holder quantity 5
Buffer Quantity: 3
Unload Process> Part Prerequisites> Tank Holder quantity 5
Machine1 Quantity: 1 Name: Minter300 Type: Shearing
Rejection Rate: 0,5%
Machine2 Quantity:1 Name: Minter300 Type: Stamping
Machine3 Quantity:1 Name: Jutec850 Type: Bending
Rejection Rate: -
Machine 4 Quantity:1 Name: Tradesman Type: Drilling
Labor Controller Quantity: 6
Depart Requirements For decision point 1,3,4,5,7,8,10,12,13,15: Any Part = 1,
Combination-1
For decision point 2,6,9,11,14,16: Any Part = all 0, no Combination
Part Destination For every decision point, add fixed part destination for Tank Holder
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Drilling
Machine
Roller Conveyor
Labor
Segment
Bending Labor
Machine
Stamping
Machine Source
Forklift
Shearing
Machine
Figure IV.23 Layout for Tank Holder Simulation
Figure IV.24 Step 1 simulation with forklift bring raw material to production
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Figure IV.25 Step 2 simulation with material in shearing and stamping machine
Figure IV.26 Step 3 simulation with material in bending machine
Figure IV.27 Step 4 simulation with material in drilling machine
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Figure IV.28 Step 5 simulation with finished tank holder going to packout
IV.3.3. Bottom Support Production

Bottom Support part in Chapter 3 in this master thesis.
Table IV.12. Data for Bottom Support Part Production

Part Quantity: 1 Name: Bottom Support
Unload Process> Part Prerequisites> Bottom Support quantity 5
Buffer Quantity: 3
Unload Process> Part Prerequisites> Bottom Support quantity 5
Rejection Rate: -
Machine 4 Quantity:1 Name: Tradesman Type: Drilling
Depart Requirements For decision point 1,3,4,5,7,8,10,12,13,15,17,19: Any Part = 1,
Combination-1
For decision point 2,6,9,11,14,16,18,20: Any Part = all 0, no
Combination
Part Destination For every decision point, add fixed part destination for Bottom
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Support
Power and Free Quantity: 1 Loop (connected) Speed: 0,3 ft/sec
Segment (for painting) Dog Spacing: 5 ft Elevation: 10 ft Arc Radius: 3 ft
Decision Point at Sink: Logic  Unload (claim capacity: 5 at this
point)
Carrier Quantity: 10 Type: MHS
Stopping space: 5 ft Locate Direction: Forward
Painting
Drilling
Bending Source
Stamping
Shearing
Figure IV.29 Layout for Bottom Support production simulation
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Figure IV.30 Step 1 with Forklift bring raw material to production area
Figure VI.31 Step 2 with material in shear and stamp machine
Figure IV.32 Step 3 with material in bend machine
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Figure IV.33 Step 4 with material in drill machine
Figure IV.34 Step 5 with finished product ready to enter paint area
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Figure IV.35 Step 6 with finished product ready to enter Packout area
IV.3.4. Top Support Production

Top Support part in Chapter 3 in this master thesis.
Table IV.13. Data for Top Support Part Production

Part Quantity: 1 Name: Top Support
Unload Process> Part Prerequisites> Top Support quantity 5
Buffer Quantity: 3
Unload Process> Part Prerequisites> Top Support quantity 5
Rejection Rate: -
Machine 4 Quantity:1 Name: Lincoln 560 Type: Welding
Rejection Rate: -
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Combination-1
Combination
Part Destination For every decision point, add fixed part destination for Bottom
Support
point)
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Paint Area
Welding
Bending
Source
Stamping
Shearing
Figure IV.36 Layout for Top Support production simulation
Figure IV.37 Step 1 with forklift bring raw material to production area
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Figure IV.38 Step 2 with material in shear and stamp machine
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Figure IV.40 Step 4 with material in weld machine
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IV.3.5. Control Panel Production

Control Panel part in Chapter 3 in this master thesis.
Table IV.14. Data for Control Panel Part Production

Part Quantity: 1 Name: Control Panel
Unload Process> Part Prerequisites> Control Panel quantity 5
Buffer Quantity: 3
Unload Process> Part Prerequisites> Control Panel quantity 5
Rejection Rate: -
Machine 4 Quantity:1 Name: RYOBI Type: Sander/Grinder
Combination-1
Combination
Part Destination For every decision point, add fixed part destination for Control
Panel
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point)
Painting
Area
Deburring
Bending
Source
Stamping
Shearing
Figure IV.43 Layout for Control Panel production simulation
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Figure IV.45 Step 2 with material in shear and stamp machine
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Figure IV.47 Step 4 with material in debur / grind machine
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IV.3.6. Tube Plugs Production

Tube Plugs in Chapter 3 in this master thesis.
Table IV.15. Data for Tube Plugs Part Production

Part Quantity: 1 Name: Tube Plugs
Unload Process> Part Prerequisites> Tube Plugs quantity 5
Buffer Quantity: 1
Unload Process> Part Prerequisites> Tube Plugs quantity 5
Machine Quantity: 1 Name: NISSEI NS60 Type: Molding
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Rejection Rate: 1%
Machine Quantity: 1 Name: ERGCT Type: Trim
Conveyor Quantity:1 Type: Roller Accumulating
Depart Requirements For decision point 1,3,4,5,7: Any Part = 1, Combination-1
Part Destination For every decision point, add fixed part destination for Tube
Plugs
Sink
Hand pallet truck
Bin
Trim machine
Mold machine
Forklift
Roller Conveyor
Source
Figure IV.50 Layout for Tube Plugs Production
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Figure IV.52 Step 2 with material in Mold and Trim machine
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IV.3.7. Leg Extensions Production

This simulation is based on Routing Sheet, Process Chart, and Flow Diagram
for Leg Extensions in Chapter 3 in this master thesis.
Table IV.16. Data for Leg Extensions Part Production

Part Quantity: 1 Name: Leg Extensions
Unload Process> Part Prerequisites> Leg Extensions quantity 5
Buffer Quantity: 1
Unload Process> Part Prerequisites> Leg Extensions quantity 5
Rejection Rate: 1%
Part Destination For every decision point, add fixed part destination for Leg
Extensions
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Sink
Hand pallet truck
Bin
Trim machine
Mold machine
Forklift
Roller Conveyor
Source
Figure IV.54 Layout for Leg Extensions Production
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IV.3.8. Knob Production

This simulation is based on Routing Sheet, Process Chart, and Flow Diagram
for Knob in Chapter 3 in this master thesis.
Table IV.17. Data for Knob Part Production

Part Quantity: 1 Name: Knob
Unload Process> Part Prerequisites> Knob quantity 5
Buffer Quantity: 1
Unload Process> Part Prerequisites> Knob quantity 5
Rejection Rate: 1%
Part Destination For every decision point, add fixed part destination for Knob
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Sink
Hand pallet truck
Bin
Trim machine
Mold machine
Forklift
Roller Conveyor
Source
Figure IV.58 Layout for Knob Production
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IV.3.9. Legs Production

Legs part in Chapter 3 in this master thesis.
Table IV.18. Data for Legs Part Production

Part Quantity: 1 Name: Legs
Unload Process> Part Prerequisites> Legs quantity 5
Buffer Quantity: 3
Unload Process> Part Prerequisites> Legs quantity 5
Machine1 Quantity: 1 Name: Big Saw 800 Type: Cutting
Rejection Rate: 1%
Machine2 Quantity:1 Name: E2 Type: Drilling
Rejection Rate: -
Machine 4 Quantity:1 Name: Grind IR525 Type: Deburring
Machine 5 Quantity:1 Name: Lincoln LR560 Type: Welding
Rejection Rate: -
Combination-1
Combination
Part Destination For every decision point, add fixed part destination for Legs
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point)
Painting
area
Welding
Deburring
Bending
Source
Welding
Cutting
Figure IV.62 Layout for Legs production simulation
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Figure IV.63 Step 1 with
Figure IV.64 Step 2 with material in cut and drill machine
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Figure IV.66 Step 4 with material in debur and weld machine
Figure IV.67 Step 5 with material ready to enter paint area
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IV.3.10. Wood Slats Production

Wood Slats part in Chapter 3 in this master thesis.
Table IV.18. Data for Wood Slats Part Production

Part Quantity: 1 Name: Wood Slats
Unload Process> Part Prerequisites> Wood Slats quantity 5
Buffer Quantity: 3
Unload Process> Part Prerequisites> Wood Slats quantity 5
Machine1 Quantity: 1 Name: Big Saw 800 Type: Cutting
Rejection Rate: 1%
Machine 2 Quantity:1 Name: Grind IR525 Type: Sanding
Combination-1
Combination
Part Destination For every decision point, add fixed part destination for Wood Slats
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point)
Cutting
Sink
Sanding
Drilling
Source
Figure IV.69 Layout for Wood Slats production simulation
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Figure IV.70 Step 1 with raw material being transported to production area
Figure IV.71 Step 2 with material in cutting and drilling machine
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Figure IV.72 Step 3 with material in sanding machine
Figure IV.73 Step 4 with finished product being transported to Packout area
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Chapter V
Conclusion
V.1. Advantages
Here is the list of advantages using Digital Factory for Facilities Planning:
1. Picture is better than words and 3D picture is better than 2D Picture.
2. Simulation is than picture and 3D simulation is better than 2D simulation.
3. People who create Digital Factory, have more understanding about their
factory than using only manual calculation.
4. From simulation in digital factory we can see animation (how our factory
working), cost/workcell, total cost, is our product really created in correct
order, bottleneck, and so on.
5. The simulation software generates reports and detailed statistics describing the
behavior of the system under study. Based on these reports, the physical
layouts, equipment selection, operating procedures, resource allocation and
utilization, inventory policies, and other important system characteristics can
be evaluated.
6. Simulation modeling is dynamic, in that the behavior of the model is tracked
over time.
7. You can play with your factory without disrupting the real one because virtual
take no cost like the real one.
8. Computer simulation allows the comparison of different alternatives and
studies various scenarios in order to select the most suitable setup.
9. Simulation can be used to predict the behavior of a manufacturing or service
system by actually tracking the movements and interaction of the system
components and aiding in optimization such systems.
10. Digital Factory can be utilized to study and optimize the layout and capacity,
JIT inventory policies, material handling systems, and warehousing and
logistics planning.
V.2. Disadvantages
Here is the list of disadvantages using Digital Factory for Facilities Planning:
1. Cost for Software is high.
2. Cost for computer hardware is high (because we need more powerful PC than
ordinary one).
3. Need time for learning software that used in digital factory.
4. Needed a lot of assumption for a new factory data.
5. If you give a wrong data, the result will be wrong (Garbage In Garbage Out).
6. Simulation is a stochastic process, meaning random occurrences must be
studied before.
7. You must understand statistic first, because simulation use distribution fitting
for data enter.
8. You must understand programming language, because sometime the software
doesn’t have logics, command, and procedures for our special case.
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Facilities Planning using Digital Factory Library
LIBRARY
 Books:
 Facilities Planning, 2nd ed. Tompkins, White, Bozer, Frazelle,

Tanchoco, Trevino. McGraw-Hill 1996.
 Production Planning and Inventory Control, 5th ed. Vincent Gasperz.

Gramedia 2005.
 Simulation using ProModel, 2nd ed. Harrel, Gosh, Bowden. McGraw-

Hill 2000.
 Reinhard, G.; Grundwald, S.; Rick, F.: Virtuelle Produktion – Virtuelle

Produkte im Rechner produzieren. In: VDI-Z, 141, (1999) 12, S. 26
 Internet:
 http://www.3ds.com. Delmia Manual Book, Dassault System.
 http://www.mcadonline.com. Free Digital Prototyping magazine
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Facilities Planning using Digital Factory Appendix
APPENDIX
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APPENDIX I
DELMIA QUEST MODELING TERMS

This section lists and describes the major QUEST modelling and terms used
throughout the QUEST documentation set and software. The terms are arranged in
alphabetical order for ease in accessing them. If a term can be used in more than one
category, the description will reference those categories, e.g., decision point can be
found under AGV decision point, conveyor decision point, etc.
Accessory Class
An accessory class is a set of accessory elements that relate to the same class level
set of data, e.g., display geometry. An accessory class can be saved with a model
file or in a separate file so as to allow its use with different models.
Accessory Element
Accessory is an element with static geometry provided for visualization purposes,
and has no effect on the simulation results.
AGV Class
An AGV class is a Material Handling System (MHS) element class. It is a set of
AGV elements that relate to the same class level set of data, e.g., display geometry,
acceleration, deceleration, process logic. An AGV class definition can be saved with
the model file, or in a separate file so as to allow its use with different models.
AGV Command
An AGV command is an instruction to an AGV to perform some action given by the
AGV controller and AGV decision points. AGV commands are processed in the
AGV process logic. Users can create their own commands.
AGV Controller
An AGV controller is an MHS element. It is used to globally control one or many
AGV classes with respect to a set of AGV decision points. Each AGV class and
decision point can only belong to one controller. An AGV controller is defined
within an AGV controller class which has an associated process logic that controls
the behavior of the AGV controller elements within the class.
AGV Controller Class

An AGV controller class is an MHS element class. It is a set of AGV controller
elements that relate to the same class level set of data, e.g., display geometry, move
mode, path mode, process logic. An AGV controller class definition can be saved
with the model file, or in a separate file so as to allow its use with different models.
AGV Controller Event

An AGV controller event is a notification to a controller that some event has
occurred involving its AGVs. In general, AGV controller events are processed by
the AGV controller and/or associated decision points either with the AGV or with
the decision point at which the event occurred. However, the decision point logic
can also be defined as a local controller to process the event.
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AGV Decision Point

An AGV decision point is an MHS element. It is a location on an AGV path
segment and can have associated characteristics. It can have an input and an output
connection. At an input connection, one or more parts can be loaded onto an AGV
that is at the decision point. At an output connection, one or more parts can be
unloaded from an AGV that is at the decision point. An AGV decision point is
defined within an AGV decision point class. By default, the behavior of an AGV at
an AGV decision point is controlled by the associated AGV controller class process
logic. Assignment of process logic at an AGV decision point will override the AGV
controller process logic.
AGV Decision Point Class

An AGV decision point class is an MHS element class. It is a set of AGV decision
points that relate to the same class level set of data, e.g., display geometry,
controller, decision point logic. An AGV decision point class definition can be
saved with the model file, or in a separate file so as to allow its use with different
models.
AGV Path
An AGV path is an arrayed list of AGV path segments and AGV decision points
that define how an AGV is going to get to its destination from its current position.
The array is dynamic in that as a path segment is exited or a decision point passed,
that entity is removed from the AGV path. An AGV path is therefore a temporary
and dynamic set of data. It is to be distinguished from an AGV path system.
AGV Path System

An AGV path system is an element. It consists of a list of AGV segments that
defines a layout. It can contain AGV decision points located on AGV segments. An
AGV path system is an element and is to be distinguished from an AGV path which
is a dynamic data attached to AGV while it is moving. AGV path system is defined
within a AGV path system class.
AGV Path System Class

An AGV path system class is an MHS element class. An AGV path system class
can have only one AGV path system element which relates to the class level set of
data, e.g., display geometry, maximum speed, direction, etc. An AGV path system
class can be saved with a model file or in a separate file so as to allow its use with
different models.
AGV Segment
An AGV segment is an entity. It is a straight line or curve section of AGV path
system. AGV segments make up AGV path systems on which AGVs can travel. An
AGV decision point must always be located on an AGV segment. An AGV segment
is defined within an AGV path system.
Aisle
An aisle is a representation of a set of racks that are usually contiguous. Racks are
made up of bins and are used for storage. This is an advanced modelling term.
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ASRS
Abbreviation for Automated Storage and Retrieval Systems.
Automated Guided Vehicle (AGV)

An AGV is an MHS element. It represents a predefined material handling construct
that can transport multiple parts from one AGV decision point to another. AGVs are
created within a class. An AGV is defined within an AGV class. The behavior of an
AGV is controlled by a combination of its AGV class process logic, working
alongside its AGV class AGV controller class process logic and/or by decision point
logic for any AGV decision point that it encounters.
Batch Control Language (BCL)

Batch Control Language (BCL) is a command script language that can be used to
build/modify and/or run QUEST simulations.
Bay
The column number of a column of bins in an aisle. Bins are used for storing the
parts. This is an advanced modelling term.
Bin
A bin is a storage location that can hold one or more parts. This is an advanced
modelling term.
Buffer
A buffer is an element. It is used to represent a storage location for parts in a model.
A buffer can have a capacity and a user-defined initial stock level for each part
class. A buffer is defined within a buffer class. A buffer element behavior is defined
by the associated buffer class process and route logic.
Buffer Class
A buffer class is an element class. It is a set of buffers that relate to the same class
level set of data, e.g., display geometry, maximum capacity, process logic, route
logic. A buffer class definition can be saved with the model file, or in a separate file
so as to allow its use with different models.
Carrier
A carrier is an MHS element. Carriers are located and travel on the power and free
segments. All carriers belong to a common class that has the common information
such as display geometry, capacity, etc.
Carrier Class
A carrier class is an MHS element class. It is a set of carrier elements that relate to
the same class level set of data, e.g., display geometry, stopping space, capacity, etc.
A carrier class can be saved with a model file or in a separate file so as to allow its
use with different models.
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Class Connections
The connection mechanism also includes class connections in a model. When the
class connection is defined between two particular classes the parts are routed from
one class of elements to another class.
Part input logic is normally called to decide the destination of a part to a particular
element when the class connections exist between two classes of elements.
Connection (Pull and Push)

The push connections are the connections between elements/classes to transfer the
parts downstream. The two sections (element connections and class connections)
refer to push connections.
For the propagation of the requests upstream, the pull connections exist between
elements and classes. Just as the regular push connection acts as a channel for
transferring parts downstream, a pull connection is the conduit for requests traveling
upstream in a system. In general, pull connections are made in the reverse order of
push connections. However, pull connections are not mandatory. In the absence of a
pull connection, the reverse of push connection is used to send requests. Pull
connections are useful in sending requests to elements from which a direct push
connection to an element does not exist.
Similar to the push class connections, pull connections can also be made at the class
level. When a request is dispatched to a class, the "Request Input Logic" set on the
class decides which element within the class actually receives the request. This logic
is executed whenever a request is dispatched to the class. "Request Input Logic" is
analogous to "Part Input Logic" for transferring parts. An element class can have
pull connections either all at the element level or all at the class. Class and element
pull connections cannot be mixed and matched.
Conveyor
A conveyor is an element. It is a transportation device that allows parts to move on
it. A conveyor has a geometry on which conveyor via points are located that define
the direction of flow and the orientation of parts as they move. A conveyor may
contain conveyor decision points. A conveyor is defined within a conveyor class. A
conveyor behavior is defined by the associated conveyor class process and route
logics as well as the process logic of the decision point class of any decision points
that are located on the conveyor.
Conveyor Class
A conveyor class is an element class. It is a set of conveyors that relate to the same
class level set of data, e.g., display geometry, maximum capacity, speed, process
logic, route logic. A conveyor class definition can be saved with the model file, or
in a separate file so as to allow its use with different models.
Conveyor Decision Point

A conveyor decision point is an MHS element. It is located on a conveyor/extruded
conveyor and it has a set of characteristics. It can have an input and/or an output
connection. At an input connection, one or more parts can be loaded onto the
conveyor. At an output connection, one or more parts can be unloaded from the
conveyor. Conveyor decision points are defined within a conveyor decision point
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class. A conveyor decision point is controlled by the decision point logic of its
associated conveyor decision point class.
Conveyor Decision Point Class

A conveyor decision point class is an MHS element class. It is a set of conveyor
decision points that relate to the same class level set of data, e.g., display geometry
or decision point logic. A conveyor decision point class definition can be saved with
Conveyor Via Path

Conveyor via path defines the movement and orientation of parts on the conveyor.
The length of the via path is usually the length of the conveyor. The conveyor via
path is defined between the starting and ending conveyor via points. Additional via
points can be added to the via path and their position/orientation can be modified.
Conveyor Via Point

A conveyor via point is an entity. It is a location on the conveyor. The via path
between two conveyor via points determines the position and orientation of a
moving part.
Coordinate System (Coorsys)

Coordinate system is abbreviated to coorsys in most cases. A coorsys is one
example of a frame. The term means a set of X, Y, Z axes with a specific location
and orientation in space. All geometries have a base coordinate system that is used
to manage the mathematical relationships involved in the computer representation
of the geometry. On occasion a geometry may have more than one coorsys.
Cost Center
A cost center is a QUEST element that performs some activity that is of importance
to the costing analysis, e.g., a source producing parts. This is an advanced modelling
term.
Cost Driver
The cost driver represents a measure of consumption of some element, e.g., machine
utilization in hours. This is an advanced modelling term.
Cost Driver Rate

The cost driver rate represents the conversion of consumption measure to a cost
measure. It converts the cost driver term to a cost measure, e.g., $24 per hour for
machine busy time. This is an advanced modelling term.
Cost Variable
The cost variable represents the source of cost expenditure, e.g., power consumed
by a machine based on the machine busy time. This is an advanced modelling term.
Crane
A crane is an MHS element that moves in an aisle storing and retrieving parts.
Cranes are used to carry parts between the pick-up and drop-off stations and the
storage bins. This is an advanced modelling term.
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Cycle Process
A cycle process is a set of data, usually entered via the GUI, that represents
production time (busy state) for a machine. A cycle process has a set of
requirements for parts, AGV, and labor that must all be present before the machine
starts the cycle process. A cycle process has a time, which can be sampled from a
distribution each time the cycle is used that specifies how long the process will take.
A cycle process also can specify what parts are produced by the process on its
completion. A cycle process can be saved with the model or as a separate file so as
to allow its use with other models. A cycle process can be associated with many
machines.
Daily Schedule
The daily schedule is the shift schedule describing the length of the operating shift
and the corresponding breaks for a 24-hour period. The daily schedule can be
applied to classes to define the time patterns of the operations of the elements of the
class.
A daily schedule can contain several breaks that define the time breaks that are non-
operational times in a day.
Decision Point
A decision point is an MHS element. A decision point is either an AGV, power and
free, labor or conveyor decision point. Example: AGV Decision Point, Conveyor
Decision Point, Labor Decision Point, Power and Free Decision Point.
Distributions
When modelling a stochastic (random) event inside of QUEST, distributions are
used to represent the probability of a given outcome occurring. The distributions
available in QUEST are:
 Constant Normal Erlang
 Uniform Triangular Lognormal
 Exponential Poisson Weibull
 Gamma Beta
QUEST also allows distribution data to be based on a Simulation Control Language
(SCL) routine, or a list of values in a file, or a user-defined probability distribution.
Drop-Off Station
A drop-off station is a location where a crane can drop off a part retrieved from a
storage bin. This is an advanced modelling term.
Element
An element is a subset of the statically created entities used to build a model. An
element has a type; e.g., it can be a sink, a source, etc. The term element is also used
to include MHS elements which are regarded as a subset of elements. An element is
defined within an element class. Parts, which are the dynamic entities of the model,
are created, transported, stored, processed, and deleted by different types of
elements.
Element Class
An element class defines a set of related elements. An element class has a type; e.g.,
it can be a sink class, a source class, etc. The term element class is also used to
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include MHS element classes which are regarded as a subset of element classes.
Each element class type has a set of data that is specified at the class level and
inherited by its elements. Class process logic and route logic defines the behavior of
its elements. Changes to the class level data is immediately inherited by its
elements. Some classes can have connections that are termed class connections.
Classes with input class connections can have input logic in order to distribute
incoming parts between elements of the class. A class definition can be saved with
Element Connections
The connection is a mechanism to logically connect the elements for the flow of
parts in a model. In an element connection an element is connected to another
element. The input/output of a particular element are created dynamically as new
connections are made. The connections can be made between like entities, i.e., class
to a class and an element to an element.
Entity
Entity describes any physical component of a model. It includes part, element, MHS
element, controller, path system, path segment, decision point, group, way point,
labor via path, device, coorsys.
Extruded Conveyor
An extruded conveyor is an element. It can be a straight line or curve section and is
created by the layout method. Parts can travel on the extruded conveyor. A
conveyor decision point can be located on an extruded conveyor. Extruded
conveyors have the same properties and behavior as regular conveyors.
Extruded Conveyor Class

An extruded conveyor class is an element class. It is a set of extruded conveyor
elements that relate to the same class level set of data, e.g., display geometry,
maximum capacity, speed, process logic, route logic, shifts, failures, etc. A
conveyor class definition can be saved with the model file, or in a separate file so as
to allow its use with different models.
In all the sections in this sub-chapter relating to conveyors, the reference to
conveyor will refer to both the extruded and non-extruded conveyors.
Failure Class
A failure class represents information on a failure and repair pattern. The failure
distribution specifies the time between failures. There is an associated repair process
that specifies the time for a repair, by a repair time distribution. Time between
failures and time to repair are independent distributions. Multiple failures can occur
at the same time. A failure definition can be saved with the model file, or in a
separate file so as to allow its use with different models. Failure classes are assigned
to element classes that are inherited by individual elements.
Frame
A frame is an entity. Frames are either way points or coorsys. A frame is really a
CAD term. A frame is a location in space (X, Y, Z) and an orientation (yaw, pitch,
and roll). A frame is most often used to identify the location and orientation of a
geometry in order to allow translation or rotation of the geometry.
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Graphical User Interface (GUI)

This is the visual and interactive mechanism by which QUEST models can be built
and run.
Group
A group is an entity. Each group is associated with a group type. It is a collection of
elements. A group can be translated or rotated as a single geometric unit. A decision
point group can be used to assist in controlling the routing of AGV/labor elements
to AGV/labor decision points. A decision point group can have a type and
associated data that can be used in AGV/labor routing decisions.
Group Type
All the groups are assigned to a group type. Users can create their own group types
by specifying the name, the entity type the group will hold (elements or AGV
decision points) and the association (single/multiple). The association specifies
whether single or multiple groups of this type can be assigned to an element.
Labor
Labor is an MHS element. It represents a predefined material handling construct
that can transport multiple parts between the elements and that may be required at
elements for a process to be performed. The QUEST labor element resembles the
laborers working on the factory floor transferring parts between the elements for
various operations and running machines. In QUEST the labor can transport
instantaneously (beam) between the elements, delay for a time, and then beam
between elements, move smoothly on a labor via path, or move smoothly on a labor
path system. Labor is defined within a labor class. The behavior of a labor element
is controlled by the process logic of its labor class working alongside the process
logic of its labor controller class, together with the process logic of any labor
decision point that it encounters.
Labor Class
A labor class is an MHS element class. It is a set of labor elements that relate to the
same class level set of data, e.g., display geometry, speed, process logic. A labor
class definition can be saved with the model file, or in a separate file so as to allow
its use with different models.
Labor Command
A labor command is an instruction to a labor element to perform some action
normally given by the labor controller. Labor commands are processed in the labor
process logic. Users can create their own commands.
Labor Controller
A labor controller is an MHS element. It is used to globally control one or many
labor classes with respect to a set of elements. Each labor class and any labor
element can only belong to one labor controller. A labor controller is defined within
a labor controller class. The behavior of a labor controller is defined by the process
logic of its labor controller class.
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Labor Controller Class

A labor controller class is an MHS element class. It is a set of labor controller
elements that relate to the same class level set of data, e.g., display geometry, speed,
move time mode, process logic. A labor controller class definition can be saved with
Labor Decision Point

A labor decision point is an MHS element. It is a location on a labor segment and
can have associated characteristics. It can have an input and/or an output
connection. At an input connection, one or more parts can be loaded onto a labor
element that is at the decision point. At an output connection, one or more parts can
be unloaded from a labor element that is at the decision point. Labor decision points
are defined within a labor decision point class. The behavior of labor at a labor
decision point is controlled by default by the associated labor controller's process
logic working alongside the associated labor class process logic. A labor decision
point's class can also have a process logic, which will override the labor controller
class process logic for that labor decision point.
Labor Decision Point Class

A labor decision point class is an MHS element class. It is a set of labor decision
points that relate to the same class level set of data, e.g., display geometry,
controller, decision point logic. A labor decision point class definition can be saved
with the model file, or in a separate file so as to allow its use with different models.
Labor Path
A labor path is an arrayed list of labor segments that defines how a labor is going to
get to its destination from its current position. The array is dynamic in that as a path
segment is exited or a decision point passed, that entity is removed from the labor
path. A labor path is therefore a temporary and dynamic set of data. It is to be
distinguished from a labor path system.
Labor Path System

A labor path system is an element. It consists of a list of labor segments that defines
a layout. It can contain labor decision points located on labor segments. A labor
path system is an element and is to be distinguished from a labor path which is a
dynamic data attached to AGV while it is moving.
Labor Path System Class

A labor path system class is an MHS element class. A labor path system class can
have only one labor path system element that relate to the class level set of data,
e.g., display geometry, maximum speed, direction, etc. A labor path system class
can be saved with a model file or in a separate file so as to allow its use with
different models.
Labor Point
A labor point is an entity. It is a location at each element. An element can have
one/or more labor points. When a labor arrives at an element it is placed at the first
available labor point.
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Labor Segment
A labor path segment is an entity. It is a straight line or curve section of labor path
system. Labor segments make up labor path systems on which labor elements can
travel. A labor decision point must always be located on a labor segment. A labor
segment is defined within a labor path system.
Labor Via Point

A labor via point is an entity. It is a location in space that determines a moving labor
element's position and orientation.
Lane
A lane is a path for a crane to move along, usually between two facing racks. This is
an advanced modelling term.
Load Process
A load process is a set of data, usually entered via the GUI, that represents loading
time for an element that supports loading. A load process has a time, which can be
sampled from a distribution each time the process is used, that specifies how long
the process will take if not interrupted. A load process can be saved with the model
or as a separate file so as to allow its use with other models.
Logic
Logic is the name for simulation rules written in Simulation Control Language
(SCL). Logic is distributed among the elements in the model. Logic governs the
behavior of the model. Many common logics are predefined and their SCL is
provided. Users may write their own logic using SCL.
Machine
A machine is an element that behaves much as a physical machine does. It can use
parts, labor, or AGVs to perform a time-taking cycle process that produces parts. It
can undergo setups, breakdowns, and repair, as well as processing parts. A machine
is defined within a machine class. The behavior of a machine is controlled by the
data, process, and route logic of its associated machine class.
Machine Class
A machine class is an element class. It is a set of machine elements that relate to the
same class level set of data, e.g., display geometry, process logic, associated
processes. A machine class definition can be saved with the model file, or in a
separate file so as to allow its use with different models.
MHS
Abbreviation for Material Handling System.
MHS Element
MHS element describes a subset of elements such as AGVs, labor, carrier.
MHS Element Class

An MHS element class contains MHS elements of the same type as the MHS
element class. The elements within a class have a set of data that they all use, e.g.,
geometry, logic. MHS element class is a subset of element class. MHS element
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class data can be saved with the model file or separately so as to allow its use with
other models.
MHS Template
The MHS template is a set of attributes for a MHS/crane. This is an advanced
modelling term.
Multi-day Schedule
This schedule is a collection of daily schedules. The user has the option of creating
different daily schedules and then creating a multi-day schedule with the daily
schedule attached to the particular day. To create a multi-day schedule at least one
daily schedule must be defined.
Part
A part is an entity that is created dynamically as the simulation runs. It moves
between elements and is processed by the system. Parts are usually generated at
sources or as a result of a machine process. Parts are usually destroyed by the sinks
or as a result of a machine process.
Parts are the entities in a discrete-event model which receive "services" from
elements, or are "processed" by them. Parts are the material and/or information
flowing through the system over time and are explicitly represented by geometries.
Part classes which specify various attributes, such as appearance and priority, may
be defined by the user. Part classes are created during the model build phase. Parts
are created and destroyed during the model run phase. A part class definition can be
models.
Part Class
It is a set of parts that relate to the same class level set of data, e.g., geometry. A
part class definition can be saved with the model file, or in a separate file so as to
allow its use with different models.
Pick-Up Station
The pick-up station is the location where the crane can collect a part to be stored.
Pick-up stations are usually modeled as buffers. This is an advanced modelling
term.
Power and Free Class

A power and free class is an MHS element class. A power and free class can have
only one P&F element that relates to the class level set of data, e.g., display
geometry, speed, dog spacing, shifts, failures, etc. A power and free class can be
saved with a model file or in a separate file so as to allow its use with different
models.
Power and Free Decision Point

A power and free decision point is an MHS element. It is a location on a power and
free segment and can have associated characteristics. It can have an input and/or an
output connection. At an input connection, one or more parts can be loaded onto a
carrier that is at the decision point. At an output connection, one or more parts can
be unloaded from a carrier that is at the decision point. A power and free decision
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point is defined within a power and free decision point class. The behavior of a
power and free decision point is controlled by the process logic of the associated
power and free decision point class.
Power and Free Decision Point Class

A power and free decision point class is an MHS element class. It is a set of power
and free decision points that relate to the same class level set of data, e.g., display
geometry, process logic. A power and free decision point class definition can be
models.
Power and Free Segment

A power and free segment is an entity. It is a straight line or curve section of power
and free system. Power and free segments make up power and free systems on
which carriers can travel. A power and free decision point must always be located
on a power and free segment. A power and free segment is defined within a power
and free system.
Power and Free System

A power and free system (sometimes referred to as P&F) is an element. It is an
arrayed list of power and free segments that defines a network of power and free
segments. Power and free decision points and carriers are located in the P&F
system.
Process
A process is a set of data, usually entered via the GUI, that controls time-taking
activities for model elements. There are different types of processes: cycle, load,
unload, repair, setup. A process can be assigned to more than one element classes. A
process definition can be saved with the model file, or in a separate file so as to
allow its use with different models. A process definition includes part/AGV/labor
requirements, process time, and products.
Rack
A rack is a set of bins used for storing the parts. This is an advanced modelling
term.
Repair Process
A repair process is a set of data, usually entered via the GUI, that represents repair
time for an element. A repair process has a time, which can be sampled from a
distribution each time the process is used, that specifies how long the process will
take. A repair process can be saved with the model or as a separate file so as to
allow its use with other models. Each repair process is associated with a Failure
class.
Setup Process
A setup process is a set of data relating to a setup on a machine. A setup process
operates on a machine. It can be assigned to be triggered before a cycle process
depending on which cycle process has just been completed and upon which cycle
process is about to start. A setup process can be saved with the model or as a
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separate file so as to allow its use with other models. Setup processes are associated
with machine classes.
Shift
A shift is a set of data that defines an availability pattern over time that specifies
when an element class is available to perform work. Shift can be defined as a daily
or a multiday schedule. Daily schedules are made up of shift breaks; multiday
schedules are made up of daily schedules.
Simulation Control Language (SCL)

Simulation Control Language (SCL) is a programming language that can be used to
make a running model behave according to the logical rules in the SCL program.
Sink
A sink is an element. It can operate in a push or in a pull mode. In a push mode, it is
a passive element, receiving parts, deleting them from the simulation and generating
statistics. In a pull mode, a sink can generate requests for parts based on an inter-
request time (IRT). In this mode, a sink can have a maximum number of part
requests and a start time for its first request. A sink has a process logic but no route
logic. A sink is defined within a sink class. The behavior of a sink is controlled by
the process of its sink class.
Sink Class
A sink class is an element class. It is a set of sinks that relate to the same class level
set of data, e.g., geometry, push/pull mode, logics. A sink class can be saved with
the model or as a separate file so as to allow its use with other models.
Source
A source is an element. It can operate in a push or in a pull mode. In a pull mode, it
is a passive element, receiving part requests, creating the parts as requested, entering
them into the simulation and generating statistics. In a push mode, a source can
generate parts based on an inter-arrival time (IAT). In this mode a source can be
constrained to the creation of a maximum number of parts and a start time for its
first part creation. A source has process logic and route logic. The behavior of a
source is controlled by the process and route logic of its source class.
Source Class
A source class is an element class. It is a set of sources that relate to the same class
level set of data, e.g., geometry, push/pull mode, logics. A source class can be saved
with the model or as a separate file so as to allow its use with other models.
Stack Point
A stack point is an entity. It represents a location in space where parts can stack.
Each element has a stack point where the parts are placed after animation.
Storage Class
A storage class is a set of storage domains to which part class storage rules can be
applied. This is an advanced modelling term.
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Storage Domain
A storage domain is a set of bins to which common storage rules can be applied.
This is an advanced modelling term.
Stream (Random Number Stream)

QUEST allows the user to create an unlimited number of random number streams.
These streams can be referenced whenever a stochastic (random) probability
distribution is applied. The default setting for QUEST is 10 random number
streams.
Tier
A tier is the row number of a row of bins in an aisle. This is an advanced modelling
term.
Unload Process
An unload process is a set of data, usually entered via the GUI, that represents
unloading time for an element class. An unload process has a time (which can be
sampled from a distribution each time the process is used) that specifies how long
the process will take. An unload process can be saved with the model or as a
separate file so as to allow its use with other models.
User Interrupts
User interrupts are user-defined interrupts that may be scheduled to occur during
simulation run time. The interrupt may be raised for any element in the QUEST
model. With this mechanism, elements may be interrupted from their current
operation and instructed to perform some other task. For example, a machine that is
busy processing, i.e., busy executing a work statement, may be interrupted in the
middle of the work, and instructed to execute some other process.
Via Point
A via point is an entity. It represents a location in space that determines a moving
element's position and orientation. There are two types of via points - labor and
conveyor.
Way Point
Way points are entities that represent a three-dimensional point in space along with
an orientation (X, Y, Z, yaw, pitch, and roll). Way points do not exist freely, they
are associated with an element or a path. A way point is a type of frame. Way points
come in several varieties, each with a specific purpose and display characteristic for
identification purposes. The way points in the system are: stack points, via points,
labor points.
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APPENDIX II
CAD MODELING TERMS

The terms are not listed alphabetically but are presented in a manner which builds on
information.
Vertex
A vertex is an X, Y, Z coordinate that is stored in the database. It is the fundamental
primitive entity from which all other entities are composed.
Point
A point may or may not be a vertex. In many functions, when prompted to indicate
a point, the current "Indicate Point Mode" determines what may be indicated. For
example, a location along an edge might be chosen, or an arbitrary location on a
surface might be chosen, regardless of the existence of a vertex at that location.
Splat
A splat is a three-dimensional cross hair that provides feedback when a point or
vertex is indicated.
Line
A line is a straight segment connecting two vertices and is represented on the screen
as "wireframe". Mathematically, a line has no area.
Polygon
A polygon is a bounded plane defined by an ordered set of vertices lying in the
plane. It must be convex and may have up to 128 sides.
Edge
The edge forms the boundaries of a polygon and may be free or shared by two
polygons.
Polyline
A polyline is as a set of connected line segments in the same subobject that
terminates at a fork, or at a segment whose interior angle (formed with the previous
segment) is less than the minimum interior angle specified in the CAD modes
function. The term polyline specifically refers to connected lines that are not part of
a B-spline curve entity. Certain CAD context functions utilize the concept of a
polyline, such as Del Line and Mov Line.
Curve
A curve is any connected set of lines. These may be a polyline, or the "flesh" of a B-
spline curve. A B-spline curve is a mathematical definition of a spatial curve that is
represented by line segments. B-splines in QUEST are "NURBS" (Non Uniform
Rational B-splines), and may be manipulated in ways different from polylines. B-
splines may be rebuilt to finer or coarser display levels, and may be frozen into
polylines. Any function referring to a curve will allow the selection of a B-spline or
a polyline. Most functions will use the exact mathematical curve when a B-spline is
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selected. Some functions may only use the line segment information, ignoring the
B-spline information.
Surface
A surface can be either a polygon or NURBS-based mathematical surface
represented with polygonal facets. As with curves, functions in the system
automatically perform the appropriate type of evaluation based on the type of
surface selected. The only time a distinction is made is for certain functions that are
polygon specific, such as Del Poly and when snapping with "Center On Polygon =
YES".
Vector
Vectors are not geometric entities but are used by certain functions in a transient
fashion. They are characterized by a direction (three numbers), and a magnitude.
Axis
An axis is similar to a vector except that there is no magnitude.
Plane
A plane is a non-geometric entity and is used in a transient manner. It is
characterized by a direction (three numbers - A, B, C) and an offset from the origin
(D). These four numbers define a locus of points in space satisfying the equation:
Ax + By + Cz + D = 0.
Coorsys
A coorsys represents a three-dimensional point in space along with an orientation.
A coorsys is created, manipulated, and deleted from the CAD context. (A coorsys
cannot be manipulated from any other context.) A coorsys is used for attaching one
part to a second part when creating devices. They can also be used to define the
positioning of way points on objects created in the CAD world and introduced
(through creation or modification of elements) in the model world. When element
geometry is introduced into the model, the translational and rotational position of
the coorsys defines the default position of the way point.
Base Coorsys
Each object (defined below) has one coorsys called its base coorsys. All geometric
entities composing the object are defined relative to this coordinate system and
object manipulations occur with respect to it.
Text
Text is represented with wireframe rendering in a font provided by DELMIA. It is a
special kind of geometric entity and should not be confused with other forms of text
in the system.
Subobject
A subobject is an arbitrary collection of polygons, lines, surfaces, curves, and text.
For example, when a block is created using the CAD | Create | Create | Block
button, an object is created that contains one subobject, which in turn contains the
polygons making up the block. If the block is then cut, there will be two new
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objects, each with one subobject. If the cut block is merged, there will be one object,
but it will now contain two subobjects.
Object
An object is an entity that is typically created in the CAD context and is composed
of subobjects and coorsys. All objects in the CAD world are automatically merged
together and saved as a single part when save is executed from CAD.
Part
Parts are named entities that are typically created in the CAD context when save is
executed. CAD parts are used as building blocks when creating a device. This CAD
part is to be distinguished from the part defined while building a QUEST model.
Device
Devices are named entities that are created automatically when elements are
created, or are imported from DELMIA's other products (IGRIP, VNC, etc.).
Devices in QUEST are generally single parts; devices imported from IGRIP (via a
QUESTCELL) may be multiple, possibly moving parts. Most QUEST elements are
single devices; however, machines may be multiple devices depending on the
definition of the element.
Joints, Links, DOFs

Joint refers to the axis of motion between rigid links, which are parts. Each joint is a
degree-of-freedom (DOF). The Model | Kin page is used to create multiple DOF
elements in QUEST.
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Rezza Prayogi - Master Thesis

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Rezza Prayogi - Master Thesis

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UNIVERSITÄT DUISBURG-ESSEN

Duisburg, 13 February 2008

Universität Duisburg-Essen (UDE)

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ABOUT THE COMPANY

1. Moryl Klebetechnik GmbH

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2. Solidworks (a part of Dassault Systemes Corporation)

SolidWorks Office Premium is the complete 3D product design solution, providing

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3. Delmia (a part of Dassault Systemes Corp)

DELMIA QUEST provides a single collaborative environment for industrial

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 Product Development (Produktentwicklung), Prof. Dr.-Ing. Diethard Bergers

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II.5. Computer Simulation ................................................................................................................ 2-3

II.6. How to Conduct Successful Facilities Planning ........................................................................ 2-4

II.6.1. Design Product ................................................................................................................... 2-4

II.6.3.3.1. The Assembly Chart ...................................................................................... 2-11

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II.6.5.2. Goals of Material Handling ...................................................................................... 2-16

II.7.1. Getting Started With Delmia Quest ................................................................................. 2-27

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Chapter IV. Building Digital Factory .................................................................................................... 4-1

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I.1. Facilities Planning

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Specify/update primary and

Determine space requirement

Develop alternative plans and

Select facilities plan

Figure I.1 Continuous improvement facilities planning cycle1

Facilities Layout design

Handling systems design

Figure I.1 Facilities planning hierarchy1

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I.2. Digital Factory

The digital factory defined (in Generic term) as a comprehensive network of

Figure I.1 Focus of the digital factory is production planning2

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A goal of the digital factory is it, proven methods, to standardize processes

Tasks of the digital factory are among other things:

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Figure I.2 Area of digital factory3

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II.1. Product Design

Figure II.1 Exploded assembly drawing

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If it is decided that the facility is to be designed to accommodate changes in

II.2. Process Design

II.3. Schedule Design

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II.4. Facilities Design

II.5. Computer Simulation

Simulation is defined as an experimental technique, usually performed on a

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Figure II.3 Computer simulations in manufacturing facilities design

Computer simulation and modeling are rapidly becoming important in the

II.6. How to Conduct Successful Facilities Planning

II.6.1. Design Product

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Figure II.4 Sample blueprint for production purpose

Table II.1 Indented Bill of Materials

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II.6.2. Takt Time and Scrap Rates Calculation

II.6.2.1. Takt Time

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