Slide 0 of 96 Manufacturing Process Layout L L L L L L L L L L M M M M D D D D D D D D G G G G G G A AA Receiving and Shipping Assembly Painting Department.

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Manufacturing Process LayoutManufacturing Process Layout

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A A AReceiving andShipping Assembly

Painting Department

Lathe DepartmentMilling

Department Drilling Department

Grinding Department

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Process (Job Shop) LayoutsProcess (Job Shop) LayoutsProcess (Job Shop) LayoutsProcess (Job Shop) Layouts

Equipment that perform similar processes are Equipment that perform similar processes are grouped togethergrouped together

Used when the operations system must handle a wide Used when the operations system must handle a wide variety of products in relatively small volumes (i.e., variety of products in relatively small volumes (i.e., flexibility is necessary)flexibility is necessary)

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Characteristics of Process LayoutsCharacteristics of Process LayoutsCharacteristics of Process LayoutsCharacteristics of Process Layouts

General-purpose equipment is usedGeneral-purpose equipment is used Changeover is rapidChangeover is rapid Material flow is intermittentMaterial flow is intermittent Material handling equipment is flexibleMaterial handling equipment is flexible Operators are highly skilledOperators are highly skilled . . .. . . moremore

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Characteristics of Process LayoutsCharacteristics of Process LayoutsCharacteristics of Process LayoutsCharacteristics of Process Layouts

Technical supervision is requiredTechnical supervision is required Planning, scheduling and controlling functions are Planning, scheduling and controlling functions are

challengingchallenging Production time is relatively longProduction time is relatively long In-process inventory is relatively highIn-process inventory is relatively high

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A Product LayoutA Product Layout

InIn

OutOut

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Product (Assembly Line) LayoutsProduct (Assembly Line) LayoutsProduct (Assembly Line) LayoutsProduct (Assembly Line) Layouts

Operations are arranged in the sequence required to Operations are arranged in the sequence required to make the productmake the product

Used when the operations system must handle a Used when the operations system must handle a narrow variety of products in relatively high volumesnarrow variety of products in relatively high volumes

Operations and personnel are dedicated to producing Operations and personnel are dedicated to producing one or a small number of productsone or a small number of products

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Characteristics of Product LayoutsCharacteristics of Product LayoutsCharacteristics of Product LayoutsCharacteristics of Product Layouts

Special-purpose equipment are usedSpecial-purpose equipment are used Changeover is expensive and lengthyChangeover is expensive and lengthy Material flow approaches continuousMaterial flow approaches continuous Material handling equipment is fixedMaterial handling equipment is fixed Operators need not be as skilledOperators need not be as skilled . . .. . . moremore

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Characteristics of Product LayoutsCharacteristics of Product LayoutsCharacteristics of Product LayoutsCharacteristics of Product Layouts

Little direct supervision is requiredLittle direct supervision is required Planning, scheduling and controlling functions are Planning, scheduling and controlling functions are

relatively straight-forwardrelatively straight-forward Production time for a unit is relatively shortProduction time for a unit is relatively short In-process inventory is relatively lowIn-process inventory is relatively low

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Description

Type of process

Product

Demand Volume Equipment

Description

Type of process

Product

Demand Volume Equipment

Sequential arrangement of activities

Continuous, mass production, mainly assembly

Standardized, made to stock

Stable High Special purpose

Process

Comparison of ProductComparison of Productand Process Layoutsand Process Layouts

Functional grouping of activities

Intermittent, job shop, batch production, mainly fabrication

Varied, made to order

Fluctuating Low General purpose

Product

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Workers Inventory

Storage space Material handling Aisles Scheduling Layout decision Goal

Advantage

Workers Inventory

Storage space Material handling Aisles Scheduling Layout decision Goal

Advantage

Limited skills Low in-process, high

finished goods Small Fixed path (conveyor) Narrow Line balancing In-l,ine, U-type Equalize work at each

station Efficiency

Process

Comparison of ProductComparison of Productand Process Layoutsand Process Layouts

Varied skills High in-process, low

finished goods Large Variable path (forklift) Wide Dynamic Functional Minimize material

handling cost Flexibility

Product

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Cellular Manufacturing (CM) LayoutsCellular Manufacturing (CM) LayoutsCellular Manufacturing (CM) LayoutsCellular Manufacturing (CM) Layouts

Grouping of machines in cellsGrouping of machines in cells Each cell results in the production of particular part familyEach cell results in the production of particular part family.. Similar parts are identified and grouped togetherSimilar parts are identified and grouped together. . Similarity can be either in shape,size or in manufacturing Similarity can be either in shape,size or in manufacturing

processprocess Operations required to produce a particular family (group) of Operations required to produce a particular family (group) of

parts are arranged in the sequence required to make that familyparts are arranged in the sequence required to make that family Used when the operations system must handle a moderate Used when the operations system must handle a moderate

variety of products in moderate volumesvariety of products in moderate volumes

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Part familiesPart familiesPart familiesPart families

Part families with similarity in shape

Part families with similarity in manufacturing process

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Original Process LayoutOriginal Process Layout

CA B Raw materials

Assembly

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Part Routing MatrixPart Routing Matrix

MachinesParts 1 2 3 4 5 6 7 8 9 10 11 12

A x x x x xB x x x xC x x xD x x x x xE x x xF x x xG x x x xH x x x

Figure 5.8Figure 5.8

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Reordered Routing MatrixReordered Routing Matrix

MachinesParts 1 2 4 8 10 3 6 9 5 7 11 12

A x x x x xD x x x x xF x x xC x x xG x x x xB x x x xH x x xE x x x

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Revised Cellular LayoutRevised Cellular Layout

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Assembly

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A B CRaw materials

Cell 1 Cell 2 Cell 3

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Automated Manufacturing CellAutomated Manufacturing CellAutomated Manufacturing CellAutomated Manufacturing Cell

Source: J. T. Black, “Cellular Manufacturing Systems Reduce Setup Time, Make Small LotProduction Economical.” Industrial Engineering (November 1983)

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Characteristics of CMCharacteristics of CMRelative to Process LayoutsRelative to Process Layouts

Characteristics of CMCharacteristics of CMRelative to Process LayoutsRelative to Process Layouts

Equipment can be less general-purposeEquipment can be less general-purpose Material handling costs are reducedMaterial handling costs are reduced Training periods for operators are shortenedTraining periods for operators are shortened In-process inventory is lowerIn-process inventory is lower Parts can be made faster and shipped more quicklyParts can be made faster and shipped more quickly Equipment can be less special-purposeEquipment can be less special-purpose Changeovers are simplifiedChangeovers are simplified Production is easier to automateProduction is easier to automate

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Flexible Manufacturing Systems (FMS)Flexible Manufacturing Systems (FMS)Flexible Manufacturing Systems (FMS)Flexible Manufacturing Systems (FMS)

FMS consists of numerous programmable machine tools connected by an automated material handling system and controlled by a common computer network

FMS combines flexibility with efficiency FMS layouts differ based on

variety of parts that the system can process size of parts processed average processing time required for part completion

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Full-Blown FMSFull-Blown FMS