Process and Material Flow Analysis Chapter 3. Data requirement for layout decisions Frequency of trips or flow of material or some other measure of interaction.

Process and Material Flow Analysis

Chapter 3

Data requirement for layout decisions

• Frequency of trips or flow of material or some other measure of interaction between departments

• Shape and size of departments• Floor space available• Location restrictions for departments, if

any• Adjacency requirements between pairs of

departments, if any

Flow pattern at 800-acre Nissan plant in Smyrna, TN

Possible flow patterns

Dendrite flow pattern

Spine flow pattern

Five types of layout

• Product layout

• Process layout

• Fixed-position layout

• Group-technology layout

• Hybrid layout

Types of Departments/LayoutsVolume

High

Medium

Low

Low Medium High Variety

Product Department

Fixed Materials Location Department

Process Department

Product Family Department

Product Layout

Fixed Location Layout

Group Technology Layout

Process Layout

Product layout

Product Layouts

L

L

L L

L M

M

M

DD

D

DG

G

G

G A

A

Product C Department

Product A Department

P

P

P

Product B Department

A

Sh

ipp

ing

Dep

artmen

t

Receivin

g D

epartm

ent

Process layout

TM

TM TM

TM

DM

DM

DM

VMM VMM BM BM

The Process Layout

L

L

L

L

L

L

L

L

L

LM

M

M

M

D

D

D

D

D

D

D

D

G

G

G

G

G

G

A A AReceiving andShipping Assembly

Painting Department

Lathe DepartmentMilling

Department Drilling Department

Grinding Department

P

P

Flow of Materials in Process Layouts

L

L

L

L

L

L

L

L

L

LM

M

M

M

D

D

D

D

D

D

D

D

G

G

G

G

G

G

A A AReceiving andShipping Assembly

Painting Department

Lathe DepartmentMilling

Department Drilling Department

Grinding Department

P

P

Group technology layout

TM

TM

TM

TM

DM

DM

DM

VMM

VMM

BM BM

Product Family (Cellular) Layout

L

L

L

L

L

L

L

L

LM

M

M

M

D D

DD

D

D

D

G

G

G G

G

G

AA

Receiving andShipping

Special Department

Rotational Parts Cell

P

P

RectangularParts Cell

Source: John S. Usher class notes

A Manufacturing Cell

Key:Key:

SS = Saw= SawLL = Lathe= LatheHMHM = Horizontal milling = Horizontal milling

machinemachineVMVM = Vertical milling machine= Vertical milling machineGG = Grinder= Grinder

Paths of three workers moving within cell

Material movement

InIn OutOutWorker 1Worker 1

Worker 2Worker 2

Worker 3Worker 3

Dir

ecti

on

of

par

t m

ove

men

t w

ith

in c

ell

Dir

ecti

on

of

par

t m

ove

men

t w

ith

in c

ell

S

L

HM

VM

G

VM

L

Final inspection

Finished part


Project (Fixed-Position) Layout

L

L

L

L

M

D DD

G

G G

G

A

A

Receiving andShipping

P

Sto

rage

Sto

rage


Hybrid layout

TM

TM TM

TM

DM

VMM BM

Hybrid Layouts• Combination of the layouts discussed.• A sample hybrid layout that has characteristics of group, process

and product layout is shown in the following figure.• A combination of group layout in manufacturing cells, product

layout in assembly area, and process layout in the general machining and finishing section is used.

TM

TM TM

TM TMDM

BM

General CharacteristicsCharacteristics Product Process Product

Family

Project

Throughput Time Low High Low Medium

Work in process Low High Low Medium

Skill Level Choice High Med-High Medium

Product Flexibility Low High Med-High High

Demand Flexibility Medium High Medium Medium

Mach Utilization High Med-Low Medium-High Medium

Worker Utilization High High High Medium

Reliability Can be low

High High Medium

Unit production cost

Low High Low High

Exercise – What Type of Layout?

• Assembly Plant ___________

• Meijers ___________

• Suburban Hospital ___________

• International Airport ___________

• Restaurant ___________

• Boeing Aircraft ___________

Automated Manufacturing Cell

Flexible Manufacturing Systems Automated machining operations, tool changers Automated material handling, computer control Designed around size of parts processed & average

processing time for parts Can process wide variety of items quickly Very few large systems exist

Progressive layout – all parts same routeClosed loop – larger variety, alternative routesLadder layout – two machines work on same partOpen field layout – most complex

Process and Material Flow Analysis Chapter 3. Data requirement for layout decisions Frequency of trips or flow of material or some other measure of interaction.

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