The Original Shareware 1.1/The Original Shareware (WeMake CDs)(Volume 1.1)(CDs, Inc)(1993).iso/10/alps3.exe/lha/MANUAL.COM/LOUT.TXT

Text File | 1990-11-27 | 28KB | 923 lines

                    SECTION I
                 LAYOUT PLANNING








































                         I-1






               GENERAL INFORMATION INPUT

   Selection number one of the main menu is for General
Information File entry.  This is where you enter the general
information about your project.  This information can then be
used to head all the printouts that you call up in this
program.  There is also, other pertinent information not used
in headers but necessary to document the project.  The
example below begins after selecting menu item number 1.
Example:
SCREEN                         KEYBOARD          PRESS
------                         --------          -----
1. Create Facilities Information File
2. Review Facilities Information File
3. Edit Facilities Information File
Enter 1,2,or 3:<1>

                               1                 ENTER

Enter your City and State:

                               ANYTOWN USA*      ENTER

Enter your Facility name:

                               MYPLANT           ENTER

Enter your Street address:

                               123 EASY ST.      ENTER

Enter today's date:

                               01/15/89          ENTER

Enter your planner's name:

                               I. M. PLANNING    ENTER

Enter your planner's telephone number:

                               202-726-5000      ENTER

      * On any input from the keyboard commas are not
allowed.  At this point you are given an opportunity to
review or edit your input as seen in the next example.

1. Create Facilities Information File
2. Review Facilities Information File
3. Edit Facilities Information File
Enter 1,2,or 3:<1>

                               2                 ENTER






                         I-2






SCREEN                         KEYBOARD          PRESS
------                         --------          -----
CITY/STATE:  ANYTOWN USA
FACILITY:    MYPLANT
ADDRESS:     123 EASY ST.
DATE:        01/15/89
PLANNER:     I. M. PLANNING
TELEPHONE:   [phone]
    =---> Press any key when ready <---=

                                                 ANY KEY

1. Edit General Facilities Information File
2. Create Operations or Department Data File
3. Review Operations or Depa rtment Data File
4. Edit Operations or Department Data File
Enter 1-4:

      At this point you are allowed the opportunity to edit
the general information you have entered or go on in the
program.  We will look at selection 1, edit option next.
1. Edit General Facilities Information File
2.  Create Operations or Department Data File
3. Review Operations or Department Data File
4. Edit Operations or Department Data File
Enter 1-4:
                               1                 ENTER

1.  ANYTOWN USA
2. MYPLANT
3. 123 EASY ST.
4. 01/15/89
5. I.  M.  PLANNING
6. 202-736-5000
Which entry do you want to edit?  Enter 1-6:

                               6                 ENTER

1. ANYTOWN USA
2. MYPLANT
3. 123 EASY ST.
4. 01/15/89
5. I.  M. PLANNING
6.  202-736-5000
Which entry do you want to edit? Enter 1-6:6
Retype Entry:

                               202-726-5000      ENTER











                         I-3






SCREEN                         KEYBOARD          PRESS
------                         --------          -----
1. ANYTOWN USA
2. MYPLANT
3. 123 EASY ST.
4. 01/15/89
5. I. M. PLANNING
6. 202-736-5000
Which entry do you want to edit? Enter 1-6:6
Retype Entry:202-726-5000
Do you want to edit another entry?  Y/N:

                               n *               ENTER
      * You will note that on the Y/N inquiries, the inquiry
is not case sensitive.  We will not spend any more time with
General Information, but will now move on to operations or
department file creation.
               OPERATIONS OR DEPARTMENT INPUT
   In this section of the program, you will be asked to input
more detailed operational data about the building under
study.  Ordinarily you aren't concerned with how many
operations there are, but rather what they are.  In this case
you will need to know how many operations are in the
building.  We need to define an operation at this point.  For
purposes of this study, an operation is any function within
the building, that has significant impact upon another
function.  This impact does not have to be flow of materials
related.  As an example, a lunch room or break area location
has impact on all of the areas within the building, and yet
these areas have nothing to do with the flow of materials
through the over all operation.  The point to keep in mind
when developing the count of your operations, is that the
support operations need consideration also.  Since the file
that you are generating now, will be used for generating
from/to pairs of operations in both flow and non flow
considerations, your list needs to be expansive enough to
include all significant impact areas.  Some areas that might
be missed are: Administration, Customer Service, Data
Collection, Engineering, Garage, Maintenance, Timekeeping,
Quality Control, etc..  While this list is not intended to be
all inclusive it should begin to direct your thoughts to
areas of non flow .
   After you have input the number of operations to be
considered the program will automatically set up that many
records.  The program will next query you to fill each field
within those records.  If you want flexibility in your file,
you might consider adding a couple of nul records to your
file for future operations or operation splits.  To do this,
increase your count by 2, and when queried beyond your list
fill the 2 remaining records with nul values by pressing
successive enters to the end.  The program then will generate
from/to pairs of operations to be used throughout the balance
of the study.  Below is an example of the procedure.






                         I-4






EXAMPLE:
SCREEN                         KEYBOARD          PRESS
------                         --------          -----
Enter the number of operations for this file:

                               22                ENTER

Enter depart ment or operation name (Up to 30 char.):

                               RCVG DOCK         ENTER

Enter dept. or op. number (Up to 4 char.):

                               R210              ENTER

Enter square footage required (No commas,up to 5 char.):

                               950               ENTER

Enter floor assigned to dept. or op. (2 char.):

                               1                 ENTER

      The procedure repeats until all 22 records are filled.
In this example assuming we had 20 operations in our list, we
then would have 2 blank records for flexibility.  Please note
the number of characters allowed in each field, as shown
within the parentheses on each query.  As in General
Information the same procedures apply for review and edit
(see page I-8).  We will now proceed into Flow of Materials.

                  FLOW OF MATERIALS INPUT

   The concept of flow of materials between operations is
universally understood.  People don't have much difficulty
understanding that a tree is felled, and trimmed of it's
branches, before it is transported to the saw mill.  At the
saw mill it is trimmed of it's bark, cut to rough dimensions
and smoothed to final dimensions.  The flow of material
continues until it becomes a roof over our heads or a chair
that we sit on.  That part of the concept is easy to
understand but, what about comparison of two or three
different types of materials?  Let's say in the example above
that we are building a house.  Let's only consider 2 x4's and
nails.  A fair tree might produce 50 2x4's.  So for 1,000
2x4's to be transported in the form of trees, possibly 7
truckloads would be involved.  Yet, in finished form, only 5
truckloads are required for the 2x4's.  Along the same lines
1,000 nails could be transported easily in an MG.  You say it
isn't possible to compare flows of different materials
because of the difference size, shape, ease of handling,etc..
To compare strictly by volume isn't right, consider the 2x4's







                            I-5






versus the nails.  The answer can be seen in the example
above.  Equity between flows can be accomplished when we do a
trip analysis of each flow, and compare trips required to
transport the volumes.
   In the flow of materials portion of the program the trip
analysis is accomplished through the use of Flow Intensity
Factors.  These factors are developed through analysis of
your containers abilities to move a standard volume a
standard distance.  Since we are only interested in relative
trends, in most cases, an empirical approach to development
of the factors will be adequate.  If your organization has
special needs for exacting development of mag counts through
methods time measurement, then you can develop your container
file independently of the program, leaving room to develop
special containers at the end of the file.  This file then
can be installed in C:\ALPS as CTR.DTA.  You will also need a
file called CTRCT.DTA, which contains your container count.
If you need assistance in this area please contact ALPS
Software.
   You need only develop your container file once.  For this
reason, the program has a query safe-guard built in to avoid
accidental erasure of this file.  A wise procedure would be
to keep a floppy disk or tape back-up of these files as well
as all others.  This one area is extremely important in all
computer operations, and probably is the most neglected.  It
isn't just the power failures that destroy files.  Be aware.
   After the container file is in place, the program walks
you through operation pair by operation pair, asking for
volumes and major containers.  When this query procedure is
completed, the program calibrates the pairs, based on the
flow intensity unit ( volume times the flow intensity
factor).  To this calibrated list an affinity value is
applied to each operation pair.  In Table 1 below you will
see the affinity values and their meanings.
   These values remain in place throughout the program until
they are reversed to become compatible with the SPACE (R)
program.  Table 2 shows those values.  During calibration you
are shown a counter to help you evaluate how fast the
calibration is progressing.  With some experience you might
be able to forecast how long the calibration will take.
   An example of this procedure is given below.
EXAMPLE:
SCREEN                         KEYBOARD          PRESS
------                         --------          -----
1.  GENERAL FACILITIES INFORMATION FILE
2. OPERATION OR DEPARTMENT DATA FILE
3. FLOW OF MATERIALS ANALYSIS FILE
4.  OTHER THAN FLOW ANALYSIS FILE
5. FIU/MAG COUNT FILE
6.  QUIT
ENTER CHOICE 1 THROUGH 6:<1>

                               5                 ENTER






                             I-6






SCREEN                         KEYBOARD          PRESS
------                         --------          -----
DO YOU NEED TO CREATE YOUR FIU/MAG FILE? Y/N:

                               Y                 ENTER

1. Create FIU/MAG File
2.  Review FIU/MAG File
3.  Edit FIU/MAG File
Enter 1,2,or 3:

                               1                 ENTER

In this section you will be asked to enter your containers
used in the flow of materials, by name and full piece
capacity, from the highest capacity per trip down to the
lowest capacity per trip.
    =---> Press any key when ready <---=

                                                 ANY KEY

Enter the number of containers for this file:

                               12                ENTER

Enter the highest capacity container name (up to 8 char.):



                               WIDGCART          ENTER

Enter the highest capacity container capacity when full:

                               26500             ENTER

Enter container name other than highest capacity:

                               GIZCART           ENTER

Enter that container's capacity:

                               22275             ENTER

       This procedure is repeated until all 12 records are
filled.  Again, if you have, say 10 containers, it is wise to
allow room for some special containers.  Everybody seems to
improvise when it comes to transporting materials.
   The review procedure can be accessed from outside the FIU
section, but still forces entrance to creation routine
through the protection query.  Each time an operation pair is
considered for volume your container list is shown on screen
so that container selection is by number.  There are several
ways that review occurs.






                             I-7






    Editing is performed just like in the General Information
section.  The only difference between the General Information
edit and subsequent edits is the presence of more than one
record.  Because of this subsequent edits include queries to
allow browsing, record by record, or going directly to a
specific record number.  Not only is this procedure at the
top of the routine but also at the end, after an affirmative
answer has been given to the question, "Do you want to edit
another record.
_____________________________________________________________

                    AFFINITY VALUES
_____________________________________________________________
Affinity       Operation Pair                Used in Flow/
Value          Closeness Required            Non Flow Studies
  4            Absolute                      Both
  3            Essential                     Both
  2            Important                     Both
  1            Ordinary Close OK             Both
  0            Unnecessary                   Both
 -2            Undesirable                   Non Flow
 -4            Extremely Undesired           Non Flow
____________________________________________________________
                        Table 1
____________________________________________________________
_____________________________________________________________
                        SPACE
                    AFFINITY VALUES
_____________________________________________________________
Affinity       Operation Pair                Used in Flow/
Value          Closeness Required            Non Flow Studies
  1            Absolute                      Both
  2            Essential                     Both
  3            Important                     Both
  4            Ordinary Close OK             Both
 5             Unnecessary                   Both
 -7            Undesirable                   Non Flow
 -10           Extremely Undesired           Non Flow
____________________________________________________________
                        Table 2
____________________________________________________________

   As has been said previously, the creation of the flow of
materials file is dependent on the from/to file of operations
previously developed and the container file.  In this routine
you will be asked for volumes between pairs.
   It is highly recommended that you use the average daily
volume developed from the 12 months immediately preceding.
In this manner you will average seasonal trends, and have
your most current statistics.  In any case, you should use
the most reliable data that you have.  The procedure is
straight forward.







                             I-8






EXAMPLE:
SCREEN                         KEYBOARD          PRESS------
--------          -----
1.  GENERAL FACILITIES INFORMATION FILE
2. OPERATION OR DEPARTMENT DATA FILE
3. FLOW OF MATERIALS ANALYSIS FILE
4.  OTHER THAN FLOW ANALYSIS FILE
5. FIU/MAG COUNT FILE
6.  QUIT
ENTER CHOICE 1 THROUGH 6:<1>

                               3                 ENTER

FROM: RCVG DOCK TO: PROCESS 1 ENTER AVG. VOLUME BETWEEN THE
PAIR (000):

                               200               ENTER

1. WIDGCART
2. GIZCART

ENTER MAJOR CONTAINER BETWEEN PAIRS:

                               1                 ENTER

      This procedure continues through the from/to list of
operations.  The next thing that happens is the calibration
routine mentioned earlier.  The screen you will see is shown
below.

               CALIBRATING FLOW
                XX PASSES MADE *
               PLEASE WAIT
               CALIBRATION COMPLETE **

      * The XX in the passes made line is a counter inserted
to allow some measurement of progress.
      ** When the calibration is complete, the computer will
beep twice and display this message.
   Having completed the flow calibration we are now ready to
move into the area of other than flow of materials.
   This is the last data file that requires entry from you in
this program.  It has the most difficult concept to master of
the entire program.  Most managers, when asked to describe
reasons for two operations to be close, have difficulty
thinking of other than flow of materials reasons for that
closeness.
   The reason that this is true, is that they are flow or
results oriented.  Their performance is measured by their
productivity.  They equate productivity to output only, and
lose sight of the fact that the productivity measure is
really a measure of the efficiency of their operations.
   There are internal factors, that are rarely if ever
considered, that influence the efficiency of a pair of





                             I-9






operations that have nothing to do with flow.  Getting a
manager who is `locked' in on flow to recognize this fact is
difficult.  In this procedure you are required to get input
from your line managers, as to how the operations should be
close for other than flow of materials reasons.
   To assist you in steering your managers away from flow
thought to other than flow thought, the following list of
reasons is provided.  This list is not intended to be all
inclusive, but is given as only a starting place.
     Sharing:  Equipment           Personnel
               Special Utilities   Special Environments
     Timeliness   Communications   Supervision
   These are all reasons that two operations should be close
to each other.  Some reasons why they should be separated are
listed below.
     Contamination       Dust                Dirt
     Noise               Safety              Security
   You should make a list of reasons for guidance of your
managers.  This list must make sense within the framework of
your organization for it to receive acceptance from your
managers.  Each manager that you ask to give other than flow
input should be given a list of operation pairs, that has
room on it for ratings and the reasons for the ratings.
Along with this they should be given the guidance list of
reasons mentioned above.  The manager should be encouraged to
work independently of other managers.  Indicate that you
value his judgement, and are not after a committee judgement.
   In this way you can average the viewpoints from all
aspects of the total operation.  It is wise to get input from
second level managers also.  Their viewpoints should tend to
reflect a less provincial scope and have a more integrating
effect, than the first level managers.
   Each manager should be encouraged to make two passes
through the list.  The first pass should be to just identify
the pairs, that in fact, have an affinity for each other.  In
this pass, when a pair is identified, the reasons for
closeness should be noted.  The second pass, then, is for
evaluating the reasons, and quantifying this evaluation into
a rating.  It is apparent that not all pairs can be
absolutely close together.  In the flow of materials routine
a proper mix of affinities of varying intensity is maintained
automatically.  Here, however, it falls upon human input to
maintain the proper mix.  Table 3 shows the ratings and the
ideal mix between the positive rated pairs.















                            I-10






_____________________________________________________________
                    AFFINITY VALUES
_____________________________________________________________
Affinity  Operation Pair           Used in Flow/    % +RATED
Value     Closeness Required       Non Flow Studies   PAIRS
  4       Absolute                 Both               10
  3       Essential                Both               20
  2       Important                Both               30
  1       Ordinary Close OK        Both               40
  0       Unnecessary              Both
 -2       Undesirable              Non Flow
 -4       Extremely Undesired      Non Flow
____________________________________________________________
                        Table 3
____________________________________________________________

   This routine allows you to input and average four managers
forms.  If you have more than four managers submitting forms,
then you will have to perform some manual computations before
input.  You should keep in mind, that if you don't handle the
manual computations properly, you can introduce bias into
your study.  An example of this would be: You have 12 forms
and you average 9 of them so that they can be input as 1 of
the 4 inputs.  What has happened in this case is the 9 forms
averaged have been reduced from 75% of the weight in the
total vote to 25%.
 The proper way to handle this situation, and exert less
energy is to total the 9 forms for input as 1, and when asked
how many forms you have enter 12.  The correct average will
then occur.
   One other area that you will need to have an answer ready
for is, where does this total operation fit on the PQ
( Product Quantity ) distribution curve?  If quantity is high
with few products then a production line opportunity exists.
On the other hand, if there are a lot of products with low
quantity then a job shop situation exists.  The areas on the
curve between these two extremes indicate modified production
line, to lined up process departments, to group production,
running from low product high quantity to high product low
quantity.  Based on your view of your total operation, you
will weight the value of other than flow ratings, when they
are combined with flow.  A rule of thumb to use is seen below
in Table 4.
















                            I-11






_____________________________________________________________
               P Q Curve Determinations

_____________________________________________________________
P Q               Enter          OTF
Area              OTF Ratio      Value     Product Quantity
PRODUCTION LINE     5            1/5       LOWEST   HIGHEST
MOD.  PROD. LINE    4            1/4       MIDLOW   MIDHIGH
LINED PROCESS DEPT. 3            1/3       MID      MID
GROUP PRODUCTION    2            1/2       MIDHIGH  MIDLOW
JOB SHOP            1            1         HIGHEST  LOWEST
____________________________________________________________
                       Table 4
____________________________________________________________

EXAMPLE:
SCREEN                         KEYBOARD          PRESS
------                         --------          -----
1.  GENERAL FACILITIES INFORMATION FILE
2. OPERATION OR DEPARTMENT DATA FILE
3. FLOW OF MATERIALS ANALYSIS FILE
4.  OTHER THAN FLOW ANALYSIS FILE
5.  FIU/MAG COUNT FILE
6.  QUIT
ENTER CHOICE 1 THROUGH 6:<1>

                               4                 ENTER

   The program will average up to four other than flow forms
for you.  You will be asked how many forms you have to
average and then will be given an opportunity to enter the
ratings from each form, operation pair by operation pair.
  If you have less than four forms, or the operation pair
in question has no rating, simply press Enter to pass.
  Your ratings should be 4= Absolute closeness, 3= Essential
closeness, 2= Important closeness, 1= Ordinary closeness,-2=
Closeness undesired, -4= Closeness Extremely undesired.
    =---> Press any key when ready <---=

                                                 ANY KEY

ENTER THE OTF PORTION OF FLOW/OTF RATIO (1 TO ?):


SCREEN                         KEYBOARD          PRESS
------                         --------          -----
                               4                 ENTER

ENTER THE NUMBER OF FORMS YOU HAVE:

                               2                 ENTER








                            I-12






SCREEN                         KEYBOARD          PRESS
------                         --------          -----
FROM: RCVG DOCK
TO: PROCESS 1
ENTER THE FIRST FORM RATING BETWEEN THE PAIR:

                               4                 ENTER

FROM: RCVG DOCK
TO: PROCESS 1
ENTER THE FIRST FORM RATING BETWEEN THE PAIR:4
ENTER THE SECOND FORM RATING BETWEEN THE PAIR:

                               3                 ENTER

FROM: RCVG DOCK
TO: PROCESS 1
ENTER THE FIRST FORM RATING BETWEEN THE PAIR:4
ENTER THE SECOND FORM RATING BETWEEN THE PAIR:3
ENTER THE THIRD FORM RATING BETWEEN THE PAIR:

                                                 ENTER

FROM: RCVG DOCK
TO: PROCESS 1
ENTER THE FIRST FORM RATING BETWEEN THE PAIR:4
ENTER THE SECOND FORM RATING BETWEEN THE PAIR:3
ENTER THE THIRD FORM RATING BETWEEN THE PAIR:
ENTER THE FOURTH FORM RATING BETWEEN THE PAIR:

                                                 ENTER

      This procedure is repeated until all of the from/to
pairs have been completed.  At that point the program
automatically starts combining flow and other than flow
rankings, and then calibrates them.  A message comes on
screen stating:
               CALIBRATING FLOW/SERVICE
   Upon completion of this calibration you are brought back
to a menu option where you can review the flow and other than
flow affinities.
                 OBTAINING PRINTOUTS

   When you elect to obtain printouts you will be given a
menu option to select printouts for:
     General Facility Information
     Operation or Department Information
     Container Information
     Flow of Materials Information
     Other than Flow of Materials Information
     Combined Flow/OTF Information
     Combined Flow/OTF Information SPACE Format
     Other than Flow Blank Survey Form






                            I-13






   You are given the option to set your paper before print.
You are asked if you want an automatic page feed before
printing.
     In order to get the menu you will be instructed to type
2 and press enter.  This will obtain the printout program for
you.





















































                         I-14