Plant Layout and Material Handling Spring 2002

1
Flow Analysis Techniques

• Class 5
• January 30, 2002

2
Todays Topics

• Review quiz 4
• Flow Analysis Tech
• Quiz 5
• Discuss Final Projects

3
Review of quiz 4

• 3,000 units/shift, 75 efficient
• 10 downtime,std 0.284 minutes 
• subtract downtime first gt then take efficiency
  (see pg 81 of text)

4
Flow Analysis Techniques

• Heart of plant layout/beginning of material
  handling
• Minimize
• Distance traveled
• Backtracking
• Cross Traffic
• Cost of production

5
Basic Types of Layout Orientation

• Process-oriented
• Dictated by large variety of parts and processes
• Product-oriented
• Core principle of Lean Mfg

6
Product-Oriented Flow Advantages

• Simple coordination
• Line of sight communication
• Less WIP
• Eliminate excessive handling

7
Product-Oriented Flow Advantages

• 5.Quality issues quickly resolved
• 6.Standardized work
• 7.Less floor space required
• 8.Foundation for continuous improvement

8
Product-O vs. Process-O

• Material flow smoother in Product-oriented layout
• Product flow has shorter travel
• Less process sequence confusion
• Product flow does have capacity restriction.
• Expensive flexible vs. cheaper specific

9
Flow Analysis Tool Groups

• Fabrication of individual parts
• Total plant flow
• People and information flow

10
Process Flow Layout
Raw Material
Storage
Machine 1
Clean
Machine 2
Weld
Machine 3
Paint
11
Product Flow Layout
Raw Material
Storage
M1
M2
M3
Clean
Weld
Paint
12
Fabrication of Individual Parts

• Four Techniques
• String diagram
• Multi-column process chart
• From-to chart
• Process chart

13
String Diagram
R
A
B
C
S
RBACS

RBS
14
Multi-Column Process Chart
15
From-to Chart
16
Process Chart (pg 118, 128)
17
Total Plant Flow

• Flow Diagram (pg 122)
• Operations Chart (pg 125)
• Flow Process Chart (pg 128)

18
Quiz 5