Systems Design & Engg Process.pdf

Systems Design is the process of defining the architecture, components, modules, interfaces, and data for a system to satisfy specified requirements. It involves translating user requirements into a detailed blueprint that guides the implementation phase. The goal is to create a well-organized and e...

Systems Design is the process of defining the architecture, components, modules, interfaces, and data for a system to satisfy specified requirements. It involves translating user requirements into a detailed blueprint that guides the implementation phase. The goal is to create a well-organized and efficient structure that meets the intended purpose while considering factors like scalability, maintainability, and performance. Objectives of Systems Design 1. Practicality : We need a system that should be targeting the set of audiences(users) corresponding to which th ey are designing. 2. Accuracy : Above system design should be designed in such a way it fulfills nearly all requirements around which it is designed be it functional or nonfunctional requirements. 3. Completeness : System design should meet all user requirements 4. Efficient : The system design should be such that it should not overuse surpassing the cost of resources nor under use as it will by now we know will result in low output and less response time(latency). 5. Reliability : The system designed should be in proximity to a failure-free environment for a certain period of time. C.A.De Leon  6. Optimization : Time and space are just likely what we do for code chunks for individual components to work in a system. 7. Scalable(flexibility) : System design should be adaptable with time as per different user needs of customers which we know will keep on changing on time. The best example here is the well-known firm: Nokia. It is the most important aspect while designing systems. SYSTEM DESIGN PROCESS The systems design process involves structured steps to develop a system that meets specific requirements while ensuring scalability, efficiency, and maintainability. Here’s a summary of the key phases: 1. Requirements Analysis: Identify and document functional and non-functional needs through stakeholder input and use cases. 2. System Architecture Design: Define the high-level structure and choose suitable architectural patterns, with visual tools like diagrams to map out system interactions. 3. Detailed Design: Break down the system into components, data structures, interfaces, and algorithms, focusing on the specifics of each part. 4. Prototyping and Modeling: Build models, mockups, or proof-of-concept versions to validate design decisions and gather early feedback. 5. Implementation Planning: Develop a detailed strategy for coding, testing, and deploying the system, including selecting the technology stack and setting a timeline. 6. Development and Coding: Write and review code for each component, using version control to manage collaboration and track changes. 7. Integration and Testing: Ensure components work together smoothly and test the system for functionality, performance, and user acceptance. 8. Deployment and Implementation: Launch the system, configure the production environment, and migrate data, followed by monitoring during the go-live phase. 9. Maintenance and Optimization: Continuously monitor, update, and optimize the system based on performance data, bug fixes, and user feedback. C.A.De Leon  10. Documentation and Handoff: Create comprehensive technical documentation and user guides, and conduct knowledge transfer sessions for smooth handover and future maintenance. APPLICATIONS OF SYSTEMS DESIGN In production environments, systems design is crucial for optimizing processes, ensuring consistent output, and maintaining efficiency across operations. Here are key applications of systems design in production: 1. Manufacturing Systems Design Production Line Layout: Design an efficient assembly line that minimizes bottlenecks and maximizes output. This includes positioning workstations, storage, and equipment to optimize flow. Automation and Robotics Integration: Implement automated systems and robotics for repetitive tasks, improving speed, accuracy, and consistency. Quality Control Systems: Design systems that integrate quality checks at various stages to reduce defects and waste. 2. Supply Chain and Logistics Inventory Management: Develop systems that monitor inventory levels in real time, ensuring raw materials and products are available when needed without overstocking. Demand Forecasting: Utilize data analytics and predictive models to design systems that forecast demand, helping in procurement and production planning. Distribution Networks: Optimize the distribution of finished products from the factory to warehouses and customers, focusing on cost-efficiency and timely delivery. 3. Production Planning and Scheduling Resource Allocation: Design systems that allocate labor, machinery, and materials effectively, avoiding idle resources and downtime. C.A.De Leon  Just-in-Time (JIT) Production: Implement JIT strategies to produce goods based on demand, reducing waste and storage costs. Capacity Planning: Design systems that account for future scaling needs, ensuring that production can meet growing demand without overextending resources. 4. Process Optimization Lean Manufacturing: Implement systems that reduce waste, such as unnecessary movements, overproduction, or waiting times, using principles like the 5S methodology and Kaizen. Six Sigma: Design systems that identify defects and process variability, using data-driven approaches to improve production quality. Workflow Automation: Automate repetitive tasks in production, such as data entry, order processing, or machine operations, to improve efficiency. 5. Safety and Compliance Systems Worker Safety Monitoring: Design systems that monitor worker safety in real time, integrating IoT devices like sensors and cameras for hazardous areas. Regulatory Compliance: Implement systems that ensure production adheres to industry standards and regulations (e.g., ISO certifications, environmental laws). Emergency Response Planning: Create systems for real-time alerts, emergency procedures, and risk mitigation strategies. 6. Data Management and Analytics Real-Time Monitoring: Implement systems that track key performance indicators (KPIs) such as production output, machine uptime, and defect rates. Predictive Maintenance: Use data analytics and AI to predict equipment failures and schedule maintenance, reducing unplanned downtime. Reporting and Dashboards: Design centralized dashboards that provide insights into production performance, helping managers make informed decisions. 7. Enterprise Resource Planning (ERP) Integration C.A.De Leon  Cross-Departmental Coordination: Integrate production systems with other business functions like finance, procurement, and HR through ERP solutions. End-to-End Visibility: Design systems that provide comprehensive visibility from raw materials procurement to final product delivery. Order Tracking: Develop systems that track orders from production through to customer delivery, ensuring transparency and efficiency. Applications in Different Industries Automotive Production: Streamlining assembly lines, integrating robotics, and using predictive maintenance to enhance vehicle manufacturing. Pharmaceutical Manufacturing: Ensuring compliance with strict regulatory standards while optimizing the production of medicines. Food and Beverage Production: Designing systems for high-speed processing and packaging, while maintaining quality and safety standards. CASE STUDY Example 1: Designing a Lean Manufacturing System for a Garment Factory Background: A garment factory produces clothing items like shirts, pants, and jackets. The production line was inefficient due to excessive inventory, long lead times, and frequent delays. The goal was to implement a lean manufacturing system to streamline the process, reduce waste, and improve production flow. C.A.De Leon Objective: Design a lean manufacturing system to reduce waste, improve workflow, and balance production lines without using any software tools. Systems Design Process: 1. Requirements Analysis: ○ Stakeholders: Factory managers, production line workers, and quality control teams were consulted. ○ Key Needs: Reduction of waste (excess inventory, waiting times). Streamlined production flow with minimal idle time. Standardized work procedures to improve consistency and quality. 2. System Architecture Design: ○ Layout Redesign: The production floor was reorganized using the cellular layout method, grouping machines and workstations by product family. ○ Kanban System: A manual Kanban system was introduced to manage inventory and material flow, ensuring just-in-time (JIT) production. ○ Value Stream Mapping (VSM): A value stream map was created to identify non-value-adding activities and eliminate bottlenecks. 3. Detailed Design: ○ Standardized Work Procedures: Standard operating procedures (SOPs) were developed for each workstation, ensuring consistent production rates and quality. ○ Visual Management: Simple visual cues like color-coded bins and boards were introduced to track work-in-progress (WIP) and guide workers on what tasks to prioritize. ○ Line Balancing: Work tasks were redistributed across stations to ensure an even workload and minimize idle time. 4. Prototyping and Modeling: ○ Mock Production Runs: A small section of the factory was used to test the new workflow and production layout. C.A.De Leon  ○ Takt Time Calculation: The optimal production rate (takt time) was calculated based on customer demand to ensure the line was neither overproducing nor underproducing. 5. Implementation Planning: ○ Kaizen Events: The implementation was planned through a series of Kaizen (continuous improvement) workshops, where workers and managers collaborated to refine processes. ○ Phased Implementation: Changes were introduced in phases, starting with one product line to test the new system before scaling it across the factory. 6. Development and Setup: ○ Physical Reorganization: Workstations and machinery were physically rearranged according to the new cellular layout. ○ Manual Kanban Cards: Kanban cards were created and distributed to control the flow of materials and production items between stations. 7. Integration and Testing: ○ Pilot Testing: The new system was piloted on a single production line, with workers following the new procedures and using visual management tools. ○ Line Balancing Tests: Adjustments were made to balance workloads across stations, ensuring smooth and continuous flow. ○ Worker Feedback: Operators provided feedback on the new processes, which was used to fine-tune the system. 8. Deployment and Implementation: ○ Full Rollout: The lean system was rolled out across the entire factory after successful piloting, with adjustments made based on initial results. ○ Training and Support: All workers were trained on the new SOPs, Kanban processes, and visual management tools. 9. Maintenance and Optimization: ○ Continuous Improvement (Kaizen): Regular Kaizen events were held to identify ongoing improvements and address any issues that arose. ○ Performance Monitoring: Metrics like production lead time, defect rates, and WIP levels were manually tracked to ensure the system was achieving its goals. 10. Documentation and Handoff: C.A.De Leon  ○ Standard Operating Procedures: Detailed SOPs were documented and made easily accessible to workers. ○ Visual Management Guides: Simple guides and posters were displayed on the production floor to reinforce the new processes and practices. Example 2: Designing a Material Handling System in a Warehouse Background: A warehouse that stores and distributes construction materials (like cement bags, steel rods, and tiles) faced inefficiencies in its material handling processes. Workers frequently spent excessive time locating and retrieving items, leading to delays in order fulfillment and higher operational costs. The warehouse management wanted to optimize material flow, reduce handling times, and improve overall efficiency. Objective: Design an efficient material handling system that optimizes the movement, storage, and retrieval of items within the warehouse using manual processes, visual aids, and physical layout improvements. Systems Design Process: 1. Requirements Analysis: ○ Stakeholders: Warehouse managers, floor workers, and logistics personnel provided insights into existing problems and operational needs. C.A.De Leon  ○ Key Needs: Reduce travel time within the warehouse. Improve material retrieval speed. Ensure safe handling and storage of heavy and bulky items. Simplify tracking of frequently used materials. 2. System Architecture Design: ○ Layout Optimization: The warehouse layout was redesigned using the ABC analysis method, which groups items based on picking frequency. High-demand items were placed closer to the loading dock. ○ Material Flow Planning: The optimal flow of materials from receiving, storage, picking, packing, and dispatch areas was mapped out to minimize cross-traffic and congestion. 3. Detailed Design: ○ Zoning and Labeling: The warehouse was divided into clearly marked zones, each with a unique color and signage to help workers quickly identify storage areas. ○ Manual Material Handling Tools: The use of trolleys, pallet jacks, and handcarts was optimized based on item size, weight, and frequency of movement. ○ FIFO System: A first-in, first-out (FIFO) method was implemented for perishable or time-sensitive materials to ensure older stock was used first. 4. Prototyping and Modeling: ○ Layout Simulation: A scaled model of the warehouse was used to test different layout configurations and determine the best arrangement for reducing travel time. ○ Mock Order Picking: Workers performed mock picking exercises to test the new layout and material handling procedures, ensuring smooth movement and easy access to high-demand items. 5. Implementation Planning: ○ Physical Reorganization Plan: The implementation involved moving storage racks, rearranging inventory, and installing visual aids such as signs, labels, and floor markings. C.A.De Leon  ○ Training and Transition: Workers were trained on the new layout, material flow processes, and safety procedures for handling heavy items. 6. Development and Setup: ○ Storage and Access Enhancements: Frequently accessed items were moved to ergonomic heights to reduce strain and speed up retrieval. Heavy items were positioned near the floor to improve safety. ○ Visual Management Tools: Color-coded labels, aisle markers, and directional arrows were installed throughout the warehouse for easy navigation. 7. Integration and Testing: ○ Pilot Testing: The new layout and material handling procedures were tested during off-peak hours to identify any bottlenecks or inefficiencies. ○ Worker Feedback: After testing, workers provided input on any challenges they faced, which was used to make minor adjustments before full implementation. 8. Deployment and Implementation: ○ Full Rollout: The new system was rolled out across the entire warehouse over a weekend to minimize disruption. Items were moved according to the new zoning plan, and visual aids were fully deployed. ○ Standard Operating Procedures (SOPs): Updated SOPs were implemented for receiving, storing, picking, and dispatching materials, ensuring consistency across all shifts. 9. Maintenance and Optimization: ○ Regular Audits: Periodic audits were conducted to ensure materials were stored in the correct zones and that the FIFO system was being followed. ○ Continuous Improvement: Kaizen (continuous improvement) sessions were held to gather worker feedback and identify ongoing opportunities for streamlining material handling. 10. Documentation and Handoff: ○ Visual Aids and Training Materials: Laminated guides and posters were placed in key areas to remind workers of the new processes and safety practices. ○ Handoff to Supervisors: Warehouse supervisors were given responsibility for ensuring compliance with the new system and making small adjustments as needed. C.A.De Leon Results and Outcomes: Reduced Travel Time: The optimized layout reduced average retrieval time by 35%, allowing for faster order fulfillment. Improved Inventory Accuracy: Zoning and labeling improvements made it easier to track inventory levels and reduced errors during picking and packing. Enhanced Safety: The ergonomic placement of heavy items and clear aisles resulted in fewer worker injuries and near-miss incidents. Increased Productivity: Workers were able to handle more orders per shift due to streamlined processes and reduced time spent searching for items. ACTIVITY Study the given case, then apply the Systems Design Principle using Systems Design Process. This will not be submitted, but will be asked during recitation. You can discuss it with your classmates. Designing a Just-In-Time (JIT) Inventory System for a Small Electronics Manufacturer Background: A small electronics manufacturer produces various components, such as circuit boards and connectors, for different clients. The company faced issues with excess inventory, high holding costs, and frequent stockouts. The goal was to design a Just-In-Time (JIT) inventory system to reduce inventory levels, minimize costs, and improve material flow without using any software tools. Objective: Design a JIT inventory system that aligns production with actual demand, reduces inventory holding costs, and improves the efficiency of material handling and production processes. Identify the following: Requirements Analysis ○ Who should be consulted? ○ What are the key needs? System Architecture Design ○ What engineering methods should be used? Kanban? Demand Forecasting? Production Scheduling? Why? Detailed Design Prototyping and Modeling C.A.De Leon  Implementation Planning Development and Setu Integration and Testing Deployment and Implementation Maintenance and Optimization Documentation and Handoff What will be the Results and Outcomes? Keywords: JIT System, Kanban, Inventory Management, Production Scheduling, Inventory Control, Demand Forecasting Tip: Know the Industrial Engineering Method to be used first, then apply its principles. Happy Aral!! Recitation on Aug 27 :))