Módulo 1

Procesos de Producción/Servicios:

Clase 3: Tipos de Distribución de Planta

 Distribution types
Distribution and location decisions depend on whether it is a Production Environment, Office Environment or Service Environment, which
facilitates the flow of materials, people and information for which various approaches have been developed2:

Fixed position distribution (or Project3)

Study the physical distribution requirements for large projects such as ships, airplanes, buildings.

Discuss its characteristics.

5. AIDAprima Cruise Ship Construction & Christening (MK timelapse GmbH)

 Distribution types
Process or service-oriented distribution (intermittent)

For productions of low volume and high variety (or customization), it is also known as production workshop, by Order or Job Shop4, each
product or service follows a particular sequence of operations.

A hospital follows this type.

6. FSJ Hospital Project (Energetic City)

 Distribution types
Office Distribution

It is specific for operations in business environments, where it is important to facilitate the movement of information.

What can you identify in the teachers' offices?

7. Interior 3D Animation of Modern Open Plan Office (3D Design Bureau)

 Distribution types
Store Distribution

Allocation of spaces for shelves, gondolas and respond to customer behavior.

It is known that the higher the product exposure rate, the higher the sales. The use of marketing techniques and product location is
required.

Have you seen the Merchandising lab?

8. Buzz 3D virtual store flythrough (Buzz 3D)

 Distribution types
Warehouse Distribution (Distribution Centers)

Consider storage spaces and minimize costs for material handling. Inventory storage and control techniques are important (ABC
Classification, for example).

The University has a General Warehouse and each laboratory has a smaller one.

Do you know their locations?

9. Warehouse 3D Animation (Derf Fil)

 Distribution types
Product Oriented Distribution

It seeks the best use of people and equipment in repetitive and continuous production of high volume and low variety (manufacturing
and assembly lines), also known as Flow-Shop.

Very common in the manufacturing environment.

Do you remember the conveyor belt in the operations workshop?

10. Plant Layout Animation - 10s lag (GSAe)

 Distribution types
Plant distribution decisions include the most optimal placement of machines, offices and desks or
service centers. An effective distribution seeks to facilitate the flow of materials, people and
information within and between areas2.

The selection of the type of distribution is linked to the type or structure of the process3, and
therefore, defines the general pattern of the workflow4.
Fixed position distribution Process or service oriented Office Distribution
(or Project) distribution (intermittent)

Store Distribution Warehouse Distribution Product Oriented Distribution

(Distribution Centers) (repetitive - continuous)
 Advantages and disadvantages of the types of Distribution
Functional Distribution, by Processes, Flexible Flow, Job-Shop or Intermittent Production

Recommended for batch production. Machines that perform similar operations are grouped in one location as
"departments“5. It is typical when there is a high variety of references to produce but with few volumes per batch.

When the product, information or customer flows throughout the operations, they will take a “route” between activities
according to their requirements1. [Milling machines ]
Intensive Care
[Adjustment ] [Winches ]
Diagnostic Imaging Surgery

[Painting ]
Recovery room

Emergency
[Orders ]
Billing
[Delivery ]
 Advantages and disadvantages of the types of Distribution
Functional Distribution, by Processes, Flexible Flow, Job-Shop or Intermittent Production

Some advantages and disadvantages of this type of distribution:

Advantages: Disadvantages:

1. Less machinery is required, and they are
better used.
2. Greater flexibility in equipment and personnel
is achieved.
3. Less investment in equipment.
4. Greater use of the facilities.
5. High degree of flexibility
6. Ease of acquiring knowledge about the
functions of each department.
7. General purpose equipment is less expensive
and requires less maintenance in contrast to
specialized equipment.
1. Extensive movements can occur reducing the
efficiency in displacement and its costs.
2. Possibly the movement of materials could not
be automated without adding high costs.
3. Process time is extended by reducing
inventory turnover and increasing the product
in process.
4. Low productivity due to the number of
preparations.
5. Longer cycle times
6. It requires more space and capital.
7. Greater difficulty in programming activities
(Prioritization or order).
 Advantages and disadvantages of the types of Distribution
Product Distribution, repetitive, in line or assembly / manufacturing lines, Flow Shop.

Machines and other auxiliary services are located according to the product's processing sequence. It is adequate when the
volume of production of a product is high and therefore, a configuration of this type allows to achieve an efficient flow of
materials at a lower cost per unit. It use special purpose machines.

Typical examples: Automotive Assembly, Self Service Cafes

3. Milling

4. Painting 2. Turning

5. Assembly and Inspection

1. Raw Materials

6. Delivery
 Advantages and disadvantages of the types of Distribution
Product Distribution, repetitive, in line or assembly / manufacturing lines, Flow Shop.

Some advantages and disadvantages of this type of distribution:

Advantages: Disadvantages :

1. The product flow is smoothed. 1. Failures in a machine or station, you can stop
2. The inventory in process is smaller. the entire production line.
3. The cycle time is less. 2. Changes in product design require major
4. Lower costs in material handling. changes in distribution.
5. Production is simplified and its planning and 3. The production rate is controlled by
control is easier. bottlenecks.
6. Less space is occupied both for work in transit 4. High investment in equipment is required.
and for temporary storage. 5. Little flexibility, since changes in products will
7. Lower material handling costs thanks to the require modifications in the installation.
use of automated systems. 6. Possible work stress due to repetitive tasks.
8. Line balancing that eliminates bottlenecks.
9. Short manufacturing cycle thanks to
continuous flow.
10. Requires less skilled labor.
 Advantages and disadvantages of the types of Distribution
Cellular Distribution, Manufacturing / Production Cells or Technological Grouping.

Assigns different machines to work cells for the manufacture of similar products. It is a derivation of Distribution By
Product and Functional Distribution (Job Shop)6.

In effect, they are small distributions per product.

Product Cell 2
Product Cell 1
Painting

Product Cell 3

Raw Materials

Delivery
 Advantages and disadvantages of the types of Distribution
Cellular Distribution, Manufacturing / Production Cells or Technological Grouping.

Some advantages and disadvantages of this type of distribution:

Advantages : Disadvantages :

1. It can increase the standardization and 1. It is not feasible for all situations, especially if
rationalization of components. the products differ in some aspect.
2. There is reliability in the estimates. 2. May require more skilled labor.
3. Operation and effective productivity of the 3. It will require investment in equipment and
machines. machinery.
4. Improves customer service.
5. Decrease overproduction times.
6. It reduces work in process and material
movements.
7. Decrease cost overruns.

The detailed design of the Cellular Distribution is difficult, given its mixed configuration, and
because of the detailed analysis of the product families and the resources necessary for their
consideration1
 Advantages and disadvantages of the types of Distribution
Cellular Distribution, Manufacturing / Production Cells or Technological Grouping.

To design such a distribution, these steps are considered6:

1. Group products into families that follow a common sequence of activities. It may require the support of computer systems for the explosion of materials.
2. Identify the dominant flow patterns of product families (parts).
3. Group machines and processes in cells.
4. Pieces that do not correspond to a particular family, should be placed in a new cell, called “Remaining Cell”

Original distribution Cell Distribution

Milling
Drills Mills
machines
(Ta) (M) Cell 1
Raw Materials

(F)

Assembly
Heat Cell 2

Raw Materials
Winches Lever Cut
treatment

Assembly
(To) (Cp)
(Tc)

Parte
Family Cell 3
Process Route Matrix
Parts Milling Heat
Winches Drills Mills Lever Cut To
family machines treatment

Raw
Assembly
Materials Cell 4
 Advantages and disadvantages of the types of Distribution
Fixed Distribution or by Projects.

They have a relatively small number of units to produce, given their large size or volume, so distributions are designed
around the product6.

The challenge to overcome is the convergence of many resources (materials, tools, people, machinery) towards a common
point, the assembly or manufacture of the product.
Final assembly Pre assembly
o Manufacturing (Cell)

Pre assembly
o Manufacturing (Cell)

Raw Materials

Raw Materials
 Advantages and disadvantages of the types of Distribution
Fixed Distribution or by Projects.

Some advantages and disadvantages of this type of distribution:

Advantages : Disadvantages :

1. It contributes to the specialization and 1. High investment in equipment for material

updating of the workforce. handling.
2. Workers identify with the process and 2. Little literature related to quantitative
product, encouraging pride in being part of it. distribution techniques.
3. High flexibility 3. High complexity in the planning and
4. Low capital investment in distribution. programming of activities.
 Design of Process
Indeed, industrial engineers design or redesign processes by selecting the necessary technical and human resources, the
appropriate type of process, and the ideal spaces and conditions.
What Student Outcomes are involved in the design of a Process?

3. Milling

4. Painting 2. Turning

5. Assembly and Inspection

1. Raw Materials

6. Delivery
 References Session 5:

1. SLACK, Nigel. Operations Management. Pearson. 7 Ed. 2013, 764 p.

2. RENDER, Barry & HEIZER, Jay. Administración de la Producción. Pearson Educación, México. 2007. 472 p.
3. KRAJEWSKI, Lee. Administración de operaciones, procesos y cadena s de valor. Pearson Prentice-Hall. 8 Ed. 2008. 754 p.
4. STEVENSON, William J. Operations Management. McGraw-Hill Irwin. 7 ed. 2012. 945 p.
5. KUMAR, S. Anil. Operations Management. New Age International. 2009. 290 p.
6. CHASE, Richard et al. Operations Management for Competitive Advantage. McGraw-Hill Higher Education, 2000 - 864 p.

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Módulo 1

Procesos de Producción/Servicios:

Clase 4: Distribución por procesos o funcional

Agenda

01. Generalidades Distribución por procesos

02. Algunos Ejemplos de distribución por procesos

(características)

03. Métodos de distribución por proceso

04. Ejemplos.

# Diseño de
Instalaciones
Distribución Por Proceso o Funcional

# Diseño de
Instalaciones
Matriz Producto-Proceso

High Product
Layout

Production
Group
Volume Medium Technology
Layout

Fixed
Process
Location
Layout
Layout

Low

Low Medium High

Product Variety
Taller de Fabricación de Muebles

# Diseño de
Instalaciones
Industria Metalmecánica.

#
Distribució
n
 Restaurantes- Funcional-
¿Cómo diseñar una cocina de
restaurante funcional?

# Diseño de
Instalaciones
 ¿Cómo se debe diseñar en detalle una
distribución por proceso?

● El área requerida por cada centro de trabajo.

● Las limitaciones sobre la forma del área asignada a cada

centro de trabajo

● El grado y la dirección del flujo entre cada centro de

trabajo (por ejemplo, número de viajes, número de cargas o
costo del flujo por distancia recorrida);

● Convención de que los centros de trabajo estén próximos

entre sí o cerca de algún punto fijo en el diseño. # Diseño de
Instalaciones
 Ejemplo- Localización

EJEMPLO 1: Una empresa del sector

metalmecánico ha agrupado sus procesos en 6
departamentos

1.Taladro rectificación.
2.Equipo NC
3.Embarque y recepción
4.Tornos y taladros.
5.Deposito de herramientas.
6.Inspección
# Diseño de
Instalaciones
 1. Definir requerimientos de espacio
Requisito
Departamento (metros cuadrados)

1. Taladro y Rectificación 1.000

2. Equipo NC 950

3. Embarque y recepción 750

4. Tornos y taladros 1.200

5. Depósito de
800
herramientas
6. Inspección 700 # Diseño de
Instalaciones
Total 5.400
2. Matriz de unidades entre departamentos
(recorridos)

Dpto. 1 2 3 4 5 6

1 * 20 20 80
2 * 10 75
3 * 15 90
4 * 70
5 *
6 * # Diseño de
Instalaciones
3. Matriz de relaciones (desde-hasta)
4. Restricciones de la empresa

Consideraciones para la empresa:

1. Embarque y recepción (3) debe

quedar donde está ahora porque se
encuentra junto a la plataforma de carga
y descarga.

2. Tornos y taladros debe quedar donde

está ahora porque los costos de
reubicación no están, en este momento,
al alcance de la empresa.
5. Realizar una distribución inicial
(actual o azar)

2 4 3
60 m

6 5 1

90 m
6. Desarrollar un plano de bloques

Dpto. 1 2 3 4 5 6
1 * 20 20 80
2 * 10 75
3 * 15 90
4 * 70
5 *
6 *
6. Combinar arreglos (Actual vs propuesta)

2 4 3 5 4 3
6 5 1 2 1 6

5 4 3 1 4 3
2 6 1 6 5 2
𝑁!
2 4 3
𝑁 − 𝑎𝑟𝑟𝑒𝑔𝑙𝑜𝑠
5 6 1
7. Desarollar un plan de bloques.

2 4 3 5 4 3
6 5 1 2 1 6

Dpto. Unid (U) Dist. actu U*Distact Dist.prop U*Dist.prop

1-2
1-4
1-6 Dpt
1 2 3 4 5 6
2-3 o.
2-5 1 * 20 20 80

3-4 2 * 10 75
3 * 15 90
3-6
4 * 70
4-5
5 *
Totales
6 *
7. Evaluación del distribución por carga distancia.

2 4 3 5 4 3
6 5 1 2 1 6
Dpto. Unid (U) Dist. actu U*Distact Dist.prop U*Dist.prop

1-2 20 3 60 1 20
1-4 20 2 40 1 20
1-6 80 2 180 1 80
2-3 10 2 20 3 30
2-5 75 2 150 1 75
3-4 15 1 15 1 15
3-6 90 3 270 1 90
4-5 70 1 70 1 70
Totales 785 400
 Ejercicio
Un almacén de cadena ha agrupado sus procesos en seis departamentos: área
de mercados (1), área de ropa (2), área de juguetes (3), área de oficinas (4),
área de recibo (5), área de despachos al por mayor (6). Se anexan como
datos la distribución actual y la matriz de carga. Por otro lado, los
departamentos (5) y (6) deben quedar donde están ahora porque se
encuentran junto a las vías de llegada y salida, y el departamento (4) debe
quedar donde está ahora porque los costos de reubicación serían muy altos.
De esta manera, usted tiene 6 posibles arreglos (combinaciones) incluyendo la
distribución actual. Para ello evalué por el método de carga-distancia cada una
de los 5 posibles arreglos que mejoré la distribución actual. Utilice la distancia
rectilínea.
Departamentos 1 2 3 4 5 6
2 4 1 1 90 20
6 3 5
2 80 100
3 50
4 10
5
6
Otro método: Minimización del costo de manejo
de materiales.
• Diseñar una distribución orientada en el proceso para minimizar el costo de
manejo de materiales.
𝑛 𝑛

𝑀𝑖𝑛 𝐶𝑇 = ෍ ෍ 𝑋𝑖𝑗 𝐶𝑖𝑗

𝑖=1 𝑗=1
Donde 𝑛 = 𝑛ú𝑚𝑒𝑟𝑜 𝑡𝑜𝑡𝑎𝑙 𝑑𝑒 𝑑𝑒𝑝𝑎𝑟𝑡𝑎𝑚𝑒𝑛𝑡𝑜𝑠.
𝑖, 𝑗 = 𝑑𝑒𝑝𝑎𝑟𝑡𝑎𝑚𝑒𝑛𝑡𝑜𝑠 𝑖𝑛𝑑𝑖𝑣𝑖𝑑𝑢𝑎𝑙𝑒𝑠.
𝑋𝑖𝑗 = 𝑁ú𝑚𝑒𝑟𝑜 𝑑𝑒 𝑐𝑎𝑟𝑔𝑎 𝑚𝑜𝑣𝑖𝑑𝑎 𝑑𝑒𝑙 𝑑𝑒𝑝𝑎𝑟𝑡𝑎𝑚𝑒𝑛𝑡𝑜 𝑖 𝑎𝑙 𝑑𝑒𝑝𝑎𝑟𝑡𝑎𝑚𝑒𝑛𝑡𝑜 𝑗
𝐶𝑖𝑗 = 𝐶𝑜𝑠𝑡𝑜 𝑑𝑒 𝑡𝑟𝑎𝑛𝑠𝑝𝑜𝑟𝑡𝑎𝑟 𝑢𝑛𝑎 𝑐𝑎𝑟𝑔𝑎 𝑒𝑛𝑡𝑟𝑒 𝑒𝑙 𝑑𝑒𝑝𝑎𝑟𝑡𝑎𝑚𝑒𝑛𝑡𝑜 𝑖 𝑎𝑙 𝑑𝑒𝑝𝑎𝑟𝑡𝑎𝑚𝑒𝑛𝑡𝑜 𝑗
 Disposición actual.

Recepción (1) Matricería (2) Pintura (3)

60 m
Pulido (4) Montaje (5) Embarque (6)

90 m

120! = 720 𝑎𝑟𝑟𝑒𝑔𝑙𝑜𝑠

# Diseño de
Instalaciones
Matriz desde –hasta (Unidades producto)

Depto Recepción(1) Matricería (2) Pintura (3) Pulido (4) Montaje (5) Embarque (6)

Recepción (1) 40 180 20 0 0

Matricería (2) 20 30 10 30
Pintura (3) 25 0 150
Pulido (4) 40 20

Montaje (5) 75
Embarque (6)

# Diseño de
Instalaciones
Matriz Costos de manejos (Euros €)

Depto Recepción(1) Matricería (2) Pintura (3) Pulido (4) Montaje (5) Embarque (6)

Recepción (1) 1 2 1 0 0
Matricería (2) 1 1 1 1
Pintura (3) 2 0 1
Pulido (4) 1 2

Montaje (5) 1
Embarque (6)

# Diseño de
Instalaciones
 𝑀𝑖𝑛 𝐶𝑇 = σ𝑛𝑖=1 σ𝑛𝑗=1 𝑋𝑖𝑗 𝐶𝑖𝑗 = 865

Depto Recepción(1) Matricería (2) Pintura (3) Pulido (4) Montaje (5) Embarque (6) Depto Recepción(1) Matricería Pintura (3) Pulido (4) Montaje (5) Embarque
(2) (6)

Recepción 1 2 1 0 0
Recepción (1) 40 180 20 0 0
(1)

Matricería 1 1 1 1
Matricería (2) 20 30 10 30
× (2)

Pintura (3) 25 0 150 Pintura (3) 2 0 1

Pulido (4) 40 20 Pulido (4) 1 2

Montaje (5) 1
Montaje (5) 75
Embarque
Embarque (6)
(6)

# Diseño de
Instalaciones
 𝑀𝑖𝑛 𝐶𝑇 = σ𝑛𝑖=1 σ𝑛𝑗=1 𝑋𝑖𝑗 𝐶𝑖𝑗 = 735

Depto Recepción(1) Matricería (2) Pintura (3) Pulido (4) Montaje (5) Embarque (6) Depto Recepción(1) Matricería Pintura (3) Pulido (4) Montaje (5) Embarque
(2) (6)

Recepción 1 1 1 0 0
Recepción (1) 40 180 20 0 0
(1)

Matricería 2 1 1 2
Matricería (2) 20 30 10 30
× (2)

Pintura (3) 25 0 150 Pintura (3) 2 0 1

Pulido (4) 40 20 Pulido (4) 1 2

Montaje (5) 1
Montaje (5) 75
Embarque
Embarque (6)
(6)

# Diseño de
Instalaciones
 𝑀𝑖𝑛 𝐶𝑇 = σ𝑛𝑖=1 σ𝑛𝑗=1 𝑋𝑖𝑗 𝐶𝑖𝑗 = 680

Depto Recepción(1) Matricería (2) Pintura (3) Pulido (4) Montaje (5) Embarque (6) Depto Recepción(1) Matricería Pintura (3) Pulido (4) Montaje (5) Embarque
(2) (6)

Recepción 1 1 1 0 0
Recepción (1) 40 180 20 0 0
(1)

Matricería 1 1 2 2
Matricería (2) 20 30 10 30
× (2)

Pintura (3) 25 0 150 Pintura (3) 0 1

Pulido (4) 40 20 Pulido (4) 1 2

Montaje (5) 1
Montaje (5) 75
Embarque
Embarque (6)
(6)

# Diseño de
Instalaciones