28645 - Industrial Systems T-AB

Learning outcomes

This course presents the main general features and mathematic models for industrial plant choice, decisions, management, design and building. Particular emphasis will be placed on feasibility-study: market study, product study, process and facilities determination, , best manufacturing set-up, productive capacity and economic measurement indexes, choice of location, optimal layout design, project development and new plant building.

Course contents

Part A (prof. Mauro Gamberi)

INTRODUCTION TO INDUSTRIAL PLANTS Definitions and fundamentals of the main industrial plants. Production systems classification. Service/process auxiliary plants. General schemes of Feasibility Study and Systematic Layout Planning.

FEASIBILITY STUDY Market analysis and demand/ supply forecasting. Best sales volume, production capacity planning. Product study and design. Process planning and process determination. Productive cycles. Auxiliary services needed for the manufacturing process. Best productive set-up. Economic analysis for industrial investments returns, investment criteria.

INDUSTRIAL LOCATION SELECTION Common features, factors and parameters for location choosing. Qualitative and quantitative models in plant location choosing. Optimization procedure with factors analysis and final plant location

Part B (prof. Riccardo Manzini)

MATERIAL FLOW ANALYSIS AND ACTIVITY ANALYSIS Product-quantity analysis. Product-quantity data sheet. Documents for the flow analysis. MAG (Magnitudo) unit of measure of material flow. Flow diagram. Group Technology (GT) & Cellular Manufacturing (CM). Clustering algorithms. Flexible manufacturing system (FMS) e flexible assembly system (FAS). Activity relationship analysis and relationship chart. Activity relationship diagram construction: Total Closeness Ratio (TCR) algorithm.

SPACE REQUIREMENTS Analytical models for the determination of space requirement. "Direct calculation method”: equipment requirements in product and process layout. Manufacturing utilization index. The production-oriented line and the average utilization index. Economic value of an industrial resource. Balancing of assembly lines and manufacturing cells: Kottas-Lau algorithm and alternative methods. Buffer sizing in manufacturing and assembly cells. Equipment and employee requirements. Multiple activity chart analysis of multi-machine assignment: employee-machine chart and analytical models (for identical machines). Automated manufacturing cell design: Robot-Machine chart; dynamic simulation for the balancingof a manufacturing cell.
Block layout: from the flow/relationship diagram to the block layout. Models and methods for the construction of the block layout: Pairwise Exchange Method, Relationship Diagramming Method and Graph-Based Methods.

LAYOUT DESIGN Quadratic Assignment Problem (QAP). ALDEP, CORELAP, interactive CORELAP and CRAFT. Logistic Re-Layout Planning (LRP - Bologna University) to support the layout design. Selection of optimal layout. Principal factors for the evaluation of a portfolio of alternative layout configurations. Specification, implementation and follow-up.

PROJECT SCHEDULING AND CARRYING OUT Graph theory and project scheduling. Critical Path Method (CPM). Resources analysis. Microsoft Project. Program Evaluation & Review Technique (PERT).

Readings/Bibliography

A. PARESCHI, Impianti Industriali, Collana Progetto Leonardo, Ed. Esculapio, Bologna, 2° Edizione 2007

Other recommended readings:

R. MANZINI, A. REGATTIERI, Manutenzione dei Sistemi di Produzione, Progetto Leonardo, Ed. Esculapio, Bologna, 2° Edizione 2007.

J.A. TOMPKINS, J.A. WHITE, E. H. FRAZELLE, J.M.A. TANCHOCO, J.TREVINO, Facilities Planning, John Wiley & Sons, INC. 1996.

R.L. FRANCIS, L.F. McGINNIS, J.A. WHITE, Facility lay-out and location: an analytical approach, 2nd Edition Prentice-Hall Inc., Englewood Cliffs, New Jersey, 1992.

F. TURCO, Principi generali di progettazione degli impianti industriali, C.L.U.P., Milano, 1990.

S. HERAGU, Facilities Design, Ed. PWS, Boston, 1997

A. BRANDOLESE, Studio del mercato e del prodotto, C.L.U.P., Milano, 1977.

D. DEL MAR, Operations and industrial management, McGraw-Hill, 1985.

A. BRANDOLESE, M. GARETTI, Processi produttivi. Criteri tecnici di scelta e progettazione, C.L.U.P., Milano, 1982.

R.J. TERSINE, Production/operations management, North Holland, New York, 1985.

M. PINEDO, X. CHAO, Operations Scheduling with applications in manufacturing and services, McGraw Hill, 1998

A. MONTE, Elementi di Impianti Industriali, Ed. Cortina, Torino, 1994, 1-2

Teaching methods

Theoretical lessons are completed by a serie of exercises and applications to allow the student to be familiar with the common design practices

Assessment methods

Written final test divided in two parts: a technical relation regarding theoretical subjects developped in the course and numerical applications

Teaching tools

Reference text: A. PARESCHI, Impianti industriali, Collana Progetto Leonardo, Ed. Esculapio, Bologna, 2° Edizione 2007.

Presentation of supporting decision models and methods, numerical examples, case studies, software and tools.

Office hours

See the website of Riccardo Manzini

See the website of Mauro Gamberi