PROCESS SELECTION

1
PROCESS SELECTION FACILITIES LAYOUT
2
Process Selection and System Design
3
Process Selection

• Variety -- How much
• Flexibility -- What degree
• Volume -- Expected output

4
Process Types

• Job Shops
• Intermittent small runs
• Batch Processing
• Intermittent moderate runs
• Repetitive/Assembly
• Semi-continuous long runs
• Continuous Processing
• Highly standardized
• Projects
• Complex, unique operations

5
Automation

• Computer-aided design and manufacturing systems
  (CAD/CAM)
• Numerically controlled (NC) machines
• Robotics
• Manufacturing cells
• Flexible manufacturing systems
• Computer-integrated manufacturing (CIM)

6
Layout
Layout the configuration of departments, work
centers, and equipment, with particular emphasis
on movement of work (customers or materials)
through the system
S4
S5
S3
S1
S2
7
Questions

• What centers should be included?
• How much space capacity does each center need?
• How should each centers space be configured?
• Where should each center be located?
• Relative Absolute locations

8
Objectives ofFacility Layout

• Minimize material handling costs
• Utilize space efficiently
• Utilize labor efficiently
• Eliminate bottlenecks
• Facilitate communication and interaction between
  workers, between workers and their supervisors,
  or between workers and customers

9

• Reduce manufacturing cycle time or customer
  service time
• Eliminate waste or redundant movement
• Facilitate the entry, exit, and placement of
  material, products, or people
• Incorporate safety and security measures
• Promote product and service quality
• Encourage proper maintenance activities
• Provide a visual control of operations or
  activities
• Provide flexibility to adapt to changing
  conditions

10
Basic Layout Types
11
Basic Layout Types

• Product Layout
• Layout that uses standardized processing
  operations to achieve smooth, rapid, high-volume
  flow
• Linear arrangement of workstations to produce a
  specific product
• Process Layout
• Layout that can handle varied processing
  requirements
• Centers/machines grouped by process they perform
• Fixed Position Layout
• Layout in which the product or project remains
  stationary workers, materials, and equipment
  are moved as needed
• Used in projects where the product cannot be moved

12
Hybrid Layouts

• Cellular layouts
• group machines into machining cells
• Flexible manufacturing systems
• automated machining material handling systems
• Mixed-model assembly lines
• produce variety of models on one line

13
Layout Formats

• Group Technology Layout
• Just-in-Time Layouts
• Assembly-lines or
• Group Technology formats
• Fixed Position Layout
• e.g. Shipbuilding

14
Manufacturing Process Layout
Milling Department
Lathe Department
Drilling Department
L
L
M
M
D
D
D
D
M
M
D
D
D
D
L
L
L
L
G
G
G
P
G
G
G
P
L
L
Painting Department
Grinding Department
L
L
A
A
A
Receiving and Shipping
Assembly
15
Service Process Layout
16
Product Layout
IN
OUT
17
A U-Shaped Production Line
18
Cellular Layout

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

19
Group Technology
One Worker, Multiple Machines
Machine 2
Machine 3
Machine 1
Materials in
Finished goods out
Machine 4
Machine 5
20
Group Technology
Parts Families
21
Group Technology
Drilling
Milling
Lathing
D
D
L
L
M
M
D
D
M
M
L
L
Grinding
L
L
M
M
G
G
Assembly
L
L
G
G
A
A
Receiving and shipping
G
G
A
A
22
Group Technology
Drilling
Milling
Lathing
D
D
L
L
M
M
D
D
M
M
L
L
Grinding
L
L
M
M
G
G
Assembly
L
L
G
G
A
A
Receiving and shipping
G
G
A
A
(a) Jumbled flows in a job shop without GT cells
23
Group Technology
Drilling
Milling
Lathing
D
D
L
L
M
M
D
D
M
M
L
L
Grinding
L
L
M
M
G
G
Assembly
L
L
G
G
A
A
Receiving and shipping
G
G
A
A
(a) Jumbled flows in a job shop without GT cells
24
Group Technology
(a) Jumbled flows in a job shop without GT cells
25
Group Technology
(b) Line flows in a job shop with three GT cells
26
Group Technology
(b) Line flows in a job shop with three GT cells
27
Group Technology
(b) Line flows in a job shop with three GT cells
28
Group Technology
(b) Line flows in a job shop with three GT cells
29
Line Balancing Heuristics

• ASSIGN TASKS IN ORDER OF
• GREATEST POSITIONAL WEIGHT
• Positional Weight Is The Sum Of Each Tasks Time
  And The Times Of All Tasks Which Follow
• MOST FOLLOWING TASKS
• Following Tasks Are All The Tasks Encountered By
  Following All The Paths From A Task Through The
  Precedence Diagram
• NOTE When Ties Occur, Assign The Task With The
  Longest Task Time

30
Examinations Of LayoutsCould Result From

• Bottlenecks
• Quality Problems
• High Scrap Rates
• Accidents Safety Hazards
• Absenteeism
• Turnover
• Complaints Morale Problems

31
Common Reasons For Redesign Of Layouts

• Changes In Design Of Products/services
• Introduction Of New Products/services
• Changes In Technology/equipment
• Changes In Volume Or Mix Of Outputs
• Improvements In Work Methods
• Compensation For Learning Curve Effect
• Compliance With Environmental Or Legal Regulations

32
Complications ToLine Balancing

• Variability Of Operations Times
• Need For Multiple Products
• Additional Zoning Constraints
• Human Resource Factors
• Negative Effects Of Short Cycles
• Constraints On Behavioral Approaches To Job
  Design
• Constraints On Incentive Plans