Material Movement

The movement of material through the

production facility is a waste because
material movement does not add value
to the product.

8/24/04

Paul A. Jensen
Operations Research Models and Methods
Copyright 2004 - All rights reserved

The amount of movement

depends on:

the set of products manufactured,

the sequence of operations (process) identified for
each product,
the assignment of machines to the operations of the
processes,
and the layout of the machines in the manufacturing
facility.

Here we assume that the first two are fixed

and we concentrate on the latter two.
2

The several generic types of

layout
TheJobshop

Theassemblylineor
flowshop

Grouptechnology

M1
M3

M2
M2

M5

M5
M1
M2
M6

M3

M6

M6

M2

M7

M1

M4

M7

M7

M6

M3

M2

Offices

Offices

M5

Offices

M4

M1

M7

M4
M3

M4

Example
Orders for products arrive as Poisson processes.
Processing begins when an order arrives.
Operations are performed in a numerical sequence.
There are no losses in the operations.

Operation Times (hours/unit)

PRODUCTS

Operation

10

Mould

0.1

0.1

De-fraze

0.3

0.5

Barrel Polish

Test

Machine

Paint

Sub-assemble

Chemical Test

Dimensional insp.

0.1

0.3

Final insp.

0.4

0.4

Weekly Demand

0.2

0.2

0.3

0.1

0.4

0.6

0.2

0.3

0.6

0.4

0.4

0.1

0.1

0.1

0.2

0.2

0.2

0.3

0.2

0.3

0.2

0.2

0.1

0.4

0.1

0.2

0.2

0.7

0.3

0.4

0.2

0.2

0.2

0.2

0.3

0.1

0.1

0.4

0.1

0.6

0.2

100

200

0.2

50

300

0.1

0.2

0.5

0.4

0.3

0.3

0.2

0.2

80

40

120

0.2

200

250

0.2

0.2

100

0.3

120

0.3

180

Machine information

Each operation requires a unique machine.

All machines operate 40 hours per week.
Assume operation times have an exponential
probability distribution.
Provide enough machines so that all
workstations are to have no more than 80%
utilization.

Space and Economic

Information
Operation

Machine Size (sq.m.)

Machine cost ($/week)

50

Value Added ($)

10

30

40

30

100

80

60

20

10

70

40

WIP requires 0.4 sq. m. floor space per unit.

Provide sufficient space at each station to
accommodate WIP 90% of the time.
Transportation cost is $0.10/unit-meter
Use a plant with length twice as great as width.
The cost of the plant is $20 per week per square
meter.
6

Design a plant that uses a job

shop (or functional) layout

M5

M6

M7

M1

M2

Offices

M3

M4

Step 1: Queuing Analysis

Machine

Do a Queuing Analysis for each

machine type
1

10

Arrival Rate

Service Rate

Number of Mach.

Spaces for WIP

Queuing Analysis
Machine

Arrival Rate

Service Rate

Number of Mach.

Spaces for WIP

1740

129

17

850

520

440

540

158

125

114

129

1270

156

11

760

200

197

200

10

1120

1740

187

142

16

Step 2: Space Analysis

Machine

Find the space requirements of each

machine type.
Find the space required for WIP.
1

10

Number

Space

Space for WIP

Total Space

10

Space analysis
Machine

Number

17

Space for Mach.

34

Space for WIP

21

23

24

36

246

Total Space

Space for Plant

25

26

24

28

11

33

26

10

35

10

13

32

16

16

34

18

Sq. M.

11

Step 3: Flow Analysis

Construct the from-to chart for weekly

flows
Machine

10

10

12

Step 4: Construct a Layout

Use a plant dimension of 12x24 with
area 288 sq. m.

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

10

11

12

13

Step 5: Economic Analysis

Plant cost:
Machine cost:
Transportation Cost
Cost of WIP
Total Cost:
How will these costs change with larger
lot sizes?
14

Design a plant that uses a

flow shop layout

We assume that each product visits each station but

receives no processing at some stations.
What do you think changes with respect to the
functional layout?
M1

M6
M2

M7

M3

Offices

M5

M4

15

Queuing and space analyses

Queuing analysis
Machine

10

Arrival Rate

Service Rate

Number of Mach.

Spaces for WIP

Space analysis
Machine

10

Number

Space

Space for WIP

Total Space

16

Flow Analysis

Construct the from-to chart for weekly

flows
Machine

10

10

17

Economic analysis

Plant cost:
Machine cost:
Cost of WIP at machines:
Cost of WIP in material movement:
Total Cost:

18

Design a plant that uses a

separate line for each product

Let moulding and final inspection be

separate departments
What will be different in this type of
layout?

19

Queuing and space analyses

for each product
Product A

Machine

10

10

Arrival Rate

Service Rate

Number of Mach.

Spaces for WIP

Total Space

Product B

Machine

Arrival Rate

Service Rate

Number of Mach.

Spaces for WIP

Total Space

20

Economic Analysis

Plant cost:
Cost of WIP at machines:
Cost of WIP in material movement:
Total Cost:
How does this cost relate to the cost of
a functional layout?
21

Design a plant that uses group

technology

Let moulding and final inspection be separate departments

M3

M2

M2
M5

M1

M2

M3

M6

M7

M4

M6

Offices

M4

M1

M7

22

Grouped operations and

families of products
PRODUCTS

Operation

10

Mould

0.1

0.1

De-fraze

0.3

0.5

Barrel Polish

0.3

Test

0.4

Machine

Paint

Sub-assemble

Chemical Test

Dimensional insp.

0.1

0.3

Final insp.

0.4

0.4

Weekly Demand

Family 1

Family 2

Family 3

0.2

0.2

GROUP

0.3

0.1

0.4

0.6

0.7

0.2

0.4

0.6

0.2

0.2

0.4

0.1

0.1

0.2

0.2

0.1

0.3

0.2

0.2

0.3

0.2

0.1

0.2

0.2

0.2

0.2

0.3

0.1

0.1

0.6

0.2

200

0.4

0.2

100

0.3

0.2

0.1

50

0.1

0.2

0.5

0.4

0.3

0.3

0.2

0.2

300

80

40

120

0.2

0.4

200

0.1

250

0.2

100

0.3

120

0.3

180

0.2

23

Family 1

Machine

1-2

1-6

1-8

2-5

2-6

2-7

3-3

3-4

3-5

1-9

Arrival Rate

Service Rate

Number of Mach.

Spaces for WIP

Total Space

Queuing
and space
analysis for
each family

Family 2

Machine

Arrival Rate

Service Rate

Number of Mach.

Spaces for WIP

Total Space

Family 3

Machine

3-6

3-7

3-9

Arrival Rate

Service Rate

Number of Mach.

Spaces for WIP

Total Space

24

Flow Analysis
Machine

1-2

1-6

1-8

1-9

2-5

2-6

2-7

3-3

3-4

3-5

3-6

3-7

3-9

10

1-2

1-6

1-8

1-9

2-5

2-6

2-7

3-3

3-4

3-5

3-6

3-7

3-9

10

25

Economic Analysis

Plant cost:
Cost of WIP at machines:
Cost of WIP in material movement:
Total Cost:

26