REPUBLIC OF THE PHILIPPINES

POLYTECHNIC UNIVERSITY OF THE PHILIPPINES

STO. TOMAS BRANCH
College of Engineering

THE USE OF MATRIX IN PRODUCTION FLOW ANALYSIS (PFA): TRANSFORMING

TRADITIONAL FUNCTIONAL LAYOUT INTO PRODUCT-ORIENTED LAYOUT

A Library Research
In Partial Fulfillment in the subject Advanced Mathematics for Industrial Engineering
INEN 30063

Submitted to

Engr. Billy Ray M. Oldan, MSEE

Submitted by

Buenviaje, Collen Keith T.

Cerbito, Mark Kenneth L.
Diana, Princess Annabelle P.
Santos, Princess Mariane A.

Date
17 March 2020

ENGR. BIILY RAY M. OLDAN, MSEE

INSTRUCTOR III
 REPUBLIC OF THE PHILIPPINES
POLYTECHNIC UNIVERSITY OF THE PHILIPPINES
STO. TOMAS BRANCH
College of Engineering

INTRODUCTION

All manufacturing companies are aligned to achieve the same key elemental
function: to convert the resources into finished products/goods. To implement this
function, manufacturers must continually strive to improve operational efficiency. They
must set their production processes to focus on quality, to hold down the costs of
materials and labor, and to eliminate all costs that add no value to the finished product. 

Industrial engineers are driven entirely by the motive of increasing efficiency and
profitability of manufacturing operations, eliminate waste in time, money, materials,
energy and other commodities. Industrial engineers are involved in all stages of
production and processing. They design new facilities from the ground up, responsible
for upgrading, expanding or reconfiguring existing facilities.

The area of operations management frequently encounter the problems of

identifying sources of delay in material flows due to complex operation sequences, size
of part population, variety of machines or number of departments, poorly designed
facility layouts, incorrect choice of machines for operations, etc. All of which can be
helped by transforming traditional functional layout into product-oriented layout.

Production Flow Analysis (PFA) is a conventional methodology used to identify

part families, cluster of work stations and associated machine groupings to which they
can be allocated in production with the use of part routings.This further creates logical
production cells able to complete parts and components promptly with simplified
material flow. The algorithms in PFA use a variety of forms of input data travel chart
(part routings), operation sequences of machine-part matrix. It generates a binary
product machine matrix using part of numbers and machine numbers to group families.
Columns represent the machines whose number and names are at the top. Rows
represent parts whose numbers and names are placed on the left. When a particular
part requires a particular machine, the operation sequence number is in the intersecting
spreadsheet cell. Sometimes, merely an “X” signifies that a particular part needs a
particular machine. PFA reduces non-value adding operations, introduces flow by
evening out bottlenecks and diminishes process variability, all of which contribute to
efficient operations management.

ENGR. BIILY RAY M. OLDAN, MSEE

INSTRUCTOR III
 REPUBLIC OF THE PHILIPPINES
POLYTECHNIC UNIVERSITY OF THE PHILIPPINES
STO. TOMAS BRANCH
College of Engineering

SAMPLE PROBLEM

PRODUCTION FLOW ANALYSIS

1. Creating Part Routing Matrix (Table 1.1)

MACHINES
PARTS
1 2 3 4 5 6 7 8 9 10 11 12
A x x x x x
B x x x x
C x x x
D x x x x x
E x x x
F x x x
G x x x x
H x x x
*x --- this part pass this machine

(Table 1.2)

MACHINES
PARTS
1 2 3 4 5 6 7 8 9 10 11 12
A 1 1 0 1 0 0 0 1 0 1 0 0
B 0 0 0 0 1 0 1 0 0 0 1 1
C 0 0 1 0 0 1 0 0 1 0 0 0
D 1 1 0 1 0 0 0 1 0 1 0 0
E 0 0 0 1 1 0 0 0 0 0 0 1
F 1 0 0 1 0 0 0 1 0 0 0 0
G 0 0 1 0 0 1 0 0 1 0 0 1
H 0 0 0 0 0 0 1 0 0 0 1 1
*x= 1 (this part pass this machine)
*blank=0 (this part did not pass this machine)

ENGR. BIILY RAY M. OLDAN, MSEE

INSTRUCTOR III
 REPUBLIC OF THE PHILIPPINES
POLYTECHNIC UNIVERSITY OF THE PHILIPPINES
STO. TOMAS BRANCH
College of Engineering

2. Converting Base-2 Numbers to Base-10 Numbers (Row). (Table 1.3)

MACHINES
PARTS
1 2 3 4 5 6 7 8 9 10 11 12
2 11
2 10
2 9
2 8
2 7
2 6
2 5
2 4
2 3
22 21 20 ∑ (row)
2 + 2 + 28 + 2 4 + 22 =
11 10
A 1 1 0 1 0 0 0 1 0 1 0 0
3348
B 0 0 0 0 1 0 1 0 0 0 1 1 27 + 25 + 21 + 20 = 163
C 0 0 1 0 0 1 0 0 1 0 0 0 29 + 26 + 23 = 584
211 + 210 + 28 + 2 4 + 22 =
D 1 1 0 1 0 0 0 1 0 1 0 0
3348
E 0 0 0 1 1 0 0 0 0 0 0 1 28 + 27 + 20 = 385
F 1 0 0 1 0 0 0 1 0 0 0 0 211 + 28 + 24 = 2320
G 0 0 1 0 0 1 0 0 1 0 0 1 29 + 26 + 23 + 20 = 585
H 0 0 0 0 0 0 1 0 0 0 1 1 26 + 22 + 20 = 67

3. Sorting Base-10 Numbers from descending values. (Table 1.4)

MACHINES
PARTS
1 2 3 4 5 6 7 8 9 1 11 12
0 ∑
211 210 29 28 27 26 25 24 23 22 21 20
A 1 1 0 1 0 0 0 1 0 1 0 0 (row)
3348
D 1 1 0 1 0 0 0 1 0 1 0 0 3348
F 1 0 0 1 0 0 0 1 0 0 0 0 2320
G 0 0 1 0 0 1 0 0 1 0 0 1 585
C 0 0 1 0 0 1 0 0 1 0 0 0 584
E 0 0 0 1 1 0 0 0 0 0 0 1 385
B 0 0 0 0 1 0 1 0 0 0 1 1 163
H 0 0 0 0 0 0 1 0 0 0 1 1 67

ENGR. BIILY RAY M. OLDAN, MSEE

INSTRUCTOR III
 REPUBLIC OF THE PHILIPPINES
POLYTECHNIC UNIVERSITY OF THE PHILIPPINES
STO. TOMAS BRANCH
College of Engineering

4. Converting Base-2 Numbers to Base-10 Numbers (Column). (Table 1.5)

MACHINES
PARTS
1 2 3 4 5 6 7 8 9 10 11 12
∑
211 210 29 28 27 26 25 24 23 22 21 20
(row)
A 27 1 1 0 1 0 0 0 1 0 1 0 0 3348
D 26 1 1 0 1 0 0 0 1 0 1 0 0 3348
F 25 1 0 0 1 0 0 0 1 0 0 0 0 2320
G 24 0 0 1 0 0 1 0 0 1 0 0 1 585
C 23 0 0 1 0 0 1 0 0 1 0 0 0 584
E 22 0 0 0 1 1 0 0 0 0 0 0 1 385
B 21 0 0 0 0 1 0 1 0 0 0 1 1 163
H 20 0 0 0 0 0 0 1 0 0 0 1 1 67
∑
22 19 22 19
(column 24 6 24 3 224 24 3 23
4 2 8 2
)

5. Sorting Base-10 Numbers from descending values. (Table 1.6)

MACHINES
PARTS
4 1 8 2 10 3 6 9 12 5 7 11
∑
28 211 24 210 22 29 26 23 20 27 25 21
(row)
A 27 1 1 1 1 1 0 0 0 0 0 0 0 3348
D 26 1 1 1 1 1 0 0 0 0 0 0 0 3348
F 25 1 1 1 0 0 0 0 0 0 0 0 0 2320
G 24 0 0 0 0 0 1 1 1 1 0 0 0 585
C 23 0 0 0 0 0 1 1 1 0 0 0 0 584
E 22 1 0 0 0 0 0 0 0 1 1 0 0 385
B 21 0 0 0 0 0 0 0 0 1 1 1 1 163
H 20 0 0 0 0 0 0 0 0 1 0 1 1 67
∑
22 22 19 19
(column 224 24 24 24 23 6 3 3
8 4 2 2
)

ENGR. BIILY RAY M. OLDAN, MSEE

INSTRUCTOR III
 REPUBLIC OF THE PHILIPPINES
POLYTECHNIC UNIVERSITY OF THE PHILIPPINES
STO. TOMAS BRANCH
College of Engineering

6. Arrange the Process (reflected through machine no.). (Table 1.7)

MACHINES
PARTS
1 2 4 8 10 3 6 9 5 7 11 12
A 1 1 1 1 1 0 0 0 0 0 0 0
D 1 1 1 1 1 0 0 0 0 0 0 0
F 1 0 1 1 0 0 0 0 0 0 0 0
G 0 0 0 0 0 1 1 1 0 0 0 1
C 0 0 0 0 0 1 1 1 0 0 0 0
E 0 0 1 0 0 0 0 0 1 0 0 1
B 0 0 0 0 0 0 0 0 1 1 1 1
H 0 0 0 0 0 0 0 0 0 1 1 1

7. Reordered Routing Matrix (Table 1.8)

MACHINES
PARTS
1 2 4 8 10 3 6 9 5 7 11 12
A x x x x x
D x x x x x
F x x x
C x x x
G x x x x
B x x x x
H x x x
E x x x

ENGR. BIILY RAY M. OLDAN, MSEE

INSTRUCTOR III
 REPUBLIC OF THE PHILIPPINES
POLYTECHNIC UNIVERSITY OF THE PHILIPPINES
STO. TOMAS BRANCH
College of Engineering

PRESENT LAYOUT PROPOSED LAYOUT (using PFA)

(Table 1.9) (Table 1.10)

ENGR. BIILY RAY M. OLDAN, MSEE

INSTRUCTOR III
 REPUBLIC OF THE PHILIPPINES
POLYTECHNIC UNIVERSITY OF THE PHILIPPINES
STO. TOMAS BRANCH
College of Engineering

CONCLUSION

Industrial Engineers are directly involved in manufacturing and operations

management. Different methods are implemented and used to enhance the
manufacturing practice changes and to focus on maximizing the productivity of the
manufacturing systems while minimizing waste - the non-value added components in
any process. Production Flow Analysis (PFA) is one of those methods and plays sn
important role in designing manufacturing cells. It uses part routings to find natural
clusters of workstations forming production cells able to complete parts and machines
swiftly with simplified material flow.

A matrix is a grid used to store or display data in a structured format. It is often

used synonymously with a table, which contains horizontal rows and vertical columns.
In Production Flow Analysis (PFA), rearranging the rows and columns, as in the second
matrix, clearly shows families of similar parts and the machines required to build them.
These machines form a workcell. As what've shown in the given sample problem, the
proposed layout (Table 1.10) became more systematic compared to the present layout
(Table 1.9) with the use of matrix in Production Flow Analysis (PFA). In conclusion, the
usage of matrix in Production Flow Analysis method creates a more simplified material
flow, a tabulation of the operations and machines in which it can be used to identify
families and come up with a proposed layout.

ENGR. BIILY RAY M. OLDAN, MSEE

INSTRUCTOR III
 REPUBLIC OF THE PHILIPPINES
POLYTECHNIC UNIVERSITY OF THE PHILIPPINES
STO. TOMAS BRANCH
College of Engineering

REFERENCE:
 Algorithms for production flow analysis , S.T.S. Daita,S.A., Irani & S. Kotamraju
(2010)
 Production Flow Analysis, D. Bennet (2015)
 Production management, W. K Holstein (2008)
 http://www.strategosinc.com/gt-production_flow_analysis.htm?
fbclid=IwAR1OUBqlVNTEiK2xJGGgjRuzekRvyHt-
dMaHvhpdE0sUKHefKh8jHEGKDQU
 https://en.m.wikipedia.org>wiki, Production flow analysis

ENGR. BIILY RAY M. OLDAN, MSEE

INSTRUCTOR III