6-1

Process Selection and Facility Layout

CHAPTER

Process Selection and Facility Layout

6-2

Process Selection and Facility Layout

Introduction

Process selection

Deciding on the way production of goods or services will be organized

Major implications

Capacity planning Layout of facilities Equipment Design of work systems

6-3

Process Selection and System Design

Facilities and Equipment

Process Selection and Facility Layout

Figure 6.1

Forecasting

Capacity Planning

Product and Service Design

Process Selection

Layout

Technological Change

Work Design

6-4

Process Selection and Facility Layout

Process Strategy

Key aspects of process strategy

Capital intensive equipment/labor Process flexibility

Adjust to changes

Design Volume technology

6-5

Process Selection and Facility Layout

Process Selection
Batch Job Shop Repetitive

Variety

How much

Flexibility

What degree
Expected output

Volume

Continuous

6-6

Process Selection and Facility Layout

Process Types

Job shop

Small scale Moderate volume

Batch

Repetitive/assembly line

High volumes of standardized goods or services

Very high volumes of non-discrete goods

Continuous

6-7

Process Selection and Facility Layout

Product Process Matrix

Figure 6.2
Process Type

Job Shop Batch

Appliance repair Emergency room Commercial bakery Classroom Lecture

Not feasible

Repetitive

Automotive assembly Automatic carwash

Continuous (flow)

Not feasible

Oil refinery Water purification

6-8

Process Selection and Facility Layout

Product Process Matrix

Figure 6.2 (contd)

Dimension Job variety Process flexibility Unit cost Volume of output Very High Very High Very High Very High Moderate Moderate Moderate Low Low Low Low High Very low Very low Very low Very low

6-9

Process Selection and Facility Layout

Automation

Automation: Machinery that has sensing and control devices that enables it to operate

Fixed automation Programmable automation

6-10 Process Selection and Facility Layout

Automation

Computer-aided design and manufacturing systems (CAD/CAM) Numerically controlled (NC) machines Robot Manufacturing cell Flexible manufacturing systems(FMS) Computer-integrated manufacturing (CIM)

6-11 Process Selection and Facility Layout

Facilities Layout

Layout: the configuration of departments, work centers, and equipment, with particular emphasis on movement of work (customers or materials) through the system

6-12 Process Selection and Facility Layout

Importance of Layout Decisions

Requires substantial investments of money and effort Involves long-term commitments Has significant impact on cost and efficiency of short-term operations

6-13 Process Selection and Facility Layout

The Need for Layout Decisions

Inefficient operations
For Example:

High Cost Bottlenecks

Changes in the design of products or services

Accidents
The introduction of new products or services

Safety hazards

6-14 Process Selection and Facility Layout

The Need for Layout Design (Contd)

Changes in environmental or other legal requirements

Changes in volume of output or mix of products Morale problems

Changes in methods and equipment

6-15 Process Selection and Facility Layout

Basic Layout Types

Product layouts Process layouts Fixed-Position layout Combination layouts

6-16 Process Selection and Facility Layout

Basic Layout Types

Product layout

Layout that uses standardized processing operations to achieve smooth, rapid, highvolume flow Layout that can handle varied processing requirements Layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed

Process layout

Fixed Position layout

6-17 Process Selection and Facility Layout

Product Layout

Figure 6.4

Raw materials or customer

Material and/or labor

Station 1 Material and/or labor

Station 2
Material and/or labor

Station 3
Material and/or labor

Station 4

Finished item

Used for Repetitive or Continuous Processing

6-18 Process Selection and Facility Layout

Advantages of Product Layout

High rate of output Low unit cost Labor specialization Low material handling cost High utilization of labor and equipment Established routing and scheduling Routing accounting and purchasing

6-19 Process Selection and Facility Layout

Disadvantages of Product Layout

Creates dull, repetitive jobs Poorly skilled workers may not maintain equipment or quality of output Fairly inflexible to changes in volume Highly susceptible to shutdowns Needs preventive maintenance Individual incentive plans are impractical

6-20 Process Selection and Facility Layout

A U-Shaped Production Line

Figure 6.6

In

4 5

Workers

6
Out

10

6-21 Process Selection and Facility Layout

Process Layout
Process Layout (functional)

Figure 6.7

Dept. A Dept. B

Dept. C Dept. D

Dept. E Dept. F

Used for Intermittent processing Job Shop or Batch

6-22 Process Selection and Facility Layout

Product Layout
Product Layout (sequential)

Figure 6.7 (contd)

Work Station 1

Work Station 2

Work Station 3

Used for Repetitive Processing Repetitive or Continuous

6-23 Process Selection and Facility Layout

Advantages of Process Layouts

Can handle a variety of processing requirements Not particularly vulnerable to equipment failures Equipment used is less costly Possible to use individual incentive plans

6-24 Process Selection and Facility Layout

Disadvantages of Process Layouts

In-process inventory costs can be high Challenging routing and scheduling Equipment utilization rates are low Material handling slow and inefficient Complexities often reduce span of supervision Special attention for each product or customer Accounting and purchasing are more involved

6-25 Process Selection and Facility Layout

Cellular Layouts

Cellular Production

Layout in which machines are grouped into a cell that can process items that have similar processing requirements The grouping into part families of items with similar design or manufacturing characteristics

Group Technology

6-26 Process Selection and Facility Layout

Functional vs. Cellular Layouts

Dimension Functional
many longer few shorter

Table 6.3 Cellular

Number of moves between departments Travel distances

Travel paths
Job waiting times Throughput time Amount of work in process Supervision difficulty Scheduling complexity Equipment utilization

variable
greater higher higher higher higher lower

fixed
shorter lower lower lower lower higher

6-27 Process Selection and Facility Layout

Other Service Layouts

Warehouse and storage layouts Retail layouts Office layouts

6-28 Process Selection and Facility Layout

Design Product Layouts: Line Balancing

Line Balancing is the process of assigning tasks to workstations in such a way that the workstations have approximately equal time requirements.

6-29 Process Selection and Facility Layout

Cycle Time

Cycle time is the maximum time allowed at each workstation to complete its set of tasks on a unit.

6-30 Process Selection and Facility Layout

Determine Maximum Output

OT O utput capacity = CT O T operating tim e per day D = Desired output rate OT CT = cycle tim e = D

6-31 Process Selection and Facility Layout

Determine the Minimum Number of Workstations Required

N =

(D)( t) OT

t = sum of task times

6-32 Process Selection and Facility Layout

Precedence Diagram

Figure 6.10

Precedence diagram: Tool used in line balancing to display elemental tasks and sequence requirements
0.1 min. 1.0 min.

a c
0.7 min.

b d
0.5 min.

A Simple Precedence Diagram

e
0.2 min.

6-33 Process Selection and Facility Layout

Example 1: Assembly Line Balancing

Arrange tasks shown in Figure 6.10 into three workstations.

Use a cycle time of 1.0 minute Assign tasks in order of the most number of followers

6-34 Process Selection and Facility Layout

Example 1 Solution
Assign Task
a c b d e -

Workstation
1

Time Remaining
1.0 0.9 0.2 1.0 1.0 0.5 0.3

Eligible
a, c c none b d e -

Revised Time Remaining

0.9 0.2

Station Idle Time

0.2 0.0 0.5 0.3 0.0 0.3 0.5

2 3

6-35 Process Selection and Facility Layout

Calculate Percent Idle Time

Idle time per cycle Percent idle time = (N)(CT)

Efficiency = 1 Percent idle time

6-36 Process Selection and Facility Layout

Line Balancing Rules

Some Heuristic (intuitive) Rules:

Assign tasks in order of most following tasks.

Count the number of tasks that follow

Assign tasks in order of greatest positional weight.

Positional weight is the sum of each tasks time and the times of all following tasks.

6-37 Process Selection and Facility Layout

Example 2

0.2

0.2

0.3

a
0.8

b
0.6

f
1.0

g
0.4

h
0.3

6-38 Process Selection and Facility Layout

Solution to Example 2

Station 1

Station 2

Station 3

Station 4

a
c

e f d

6-39 Process Selection and Facility Layout

Parallel Workstations
1 min. 30/hr. 2 min. 30/hr. 1 min. 30/hr.

1 min.

30/hr.

Bottleneck
30/hr. 1 min.
60/hr. 1 min. 30/hr.

1 min.
30/hr. 1 min. 30/hr.

1 min.

60/hr.

Parallel Workstations

6-40 Process Selection and Facility Layout

Designing Process Layouts

Information Requirements: 1. List of departments 2. Projection of work flows 3. Distance between locations 4. Amount of money to be invested 5. List of special considerations 6. Location of key utilities

6-41 Process Selection and Facility Layout

Figure 6.12

Example 3: Interdepartmental Work Flows for Assigned Departments

30
1

170

10 0

6-42 Process Selection and Facility Layout

Authors note:

The following three slides are not in the 8e, but I like to use them for alternate examples.

6-43 Process Selection and Facility Layout

Process Layout
Milling

Assembly & Test

Grinding

Drilling

Plating

Process Layout - work travels to dedicated process centers

6-44 Process Selection and Facility Layout

Functional Layout

222 444

Mill

222 111 444

222

Drill
1111 2222

Grind

3333

111 333
111 333

Assembly
111

Lathes

Heat treat

Gear cutting

111 444

6-45 Process Selection and Facility Layout

Cellular Manufacturing Layout

Lathe Mill Drill
Heat treat Heat treat Gear -1111 cut Grind - 2222 Assembly

-1111

222222222

Mill

Drill

3333333333

Lathe Mill

Heat treat
Drill

Grind - 3333

44444444444444

Mill

Gear - 4444 cut

6-46 Process Selection and Facility Layout

Flexible Manufacturing

VD7 Process at Trek Bikes

6-47 Process Selection and Facility Layout

Location/Criteria

PS11 Guitar site location

6-48 Process Selection and Facility Layout

Process Overview

AB2 Aluminum tubing, suppliers at Hillerich & Bradsby