Professional Documents
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Process Selection and Facility Layout
Process Selection and Facility Layout
Process Selection and Facility Layout
Facility Layout
Process types, process
selection and automation
The ways organizations choose to produce or
provide their goods and services.
It involves choice of technology, type of
processing, and so on.
It influences
◦ Capacity planning
◦ Layout of facilities
◦ Equipment
◦ Design of work systems
Facilities and
Forecasting Capacity
Equipment
Planning
Process
Selection Work
Technological
Design
Change
◦ How much
Project Job Shop Repetitive
Flexibility
◦ What degree
Continuous
Volume
◦ Expected output
Project: A non-repetitive set of activities directed toward a
unique goal within a limited time frame
◦ Unique
◦ Examples: Building a bridge, consulting
Job shop: provides unit or lot production or service with
changeable specifications, according to customer needs
◦ Small scale
◦ Examples: Machine shop, dentist’s office
Batch: Produces many different products in groups (batches)
◦ Low or Moderate volume
◦ Examples: Bakeries, movie theaters, classrooms
Repetitive: provides one or a few highly standardized
products or services
◦ High volumes of standardized goods or services
◦ Examples: automobiles, computers, cafeteria, car wash
Programmable automation
◦ Computer-aided design and manufacturing systems (CAD/CAM)
◦ Numerically controlled (NC) machines: Machines that perform
operations by following mathematical processing instructions.
◦ Robot: A machine consisting of a mechanical arm, a power supply
and a controller
Flexible automation
◦ Manufacturing cell
◦ Flexible manufacturing systems
◦ Computer-integrated manufacturing (CIM)
FMS are more fully automated versions of cellular
manufacturing: A computer controls the transfer of
parts from machine to machine as well as the start of
work at each machine
Produce a variety of similar products
Classification of production
systems and types of layouts
The arrangement of departments, work centers,
and equipment, with particular emphasis on
movement of work (customers or materials)
through the system.
Inefficient operations
For Example: Changes in the design
High Cost of products or services
Bottlenecks
Accidents
The introduction of new
products or services
Safety hazards
Changes in
environmental Changes in volume of
or other legal output or mix of
requirements products
Morale problems
Changes in methods
or equipment
Product Layouts most helpful to repetitive processing
Process Layouts used for irregular processing
Fixed-position layouts used when projects require layouts
Hybrid layouts combinations of these above types
• Cellular manufacturing
• Group technology
• Flexible Manufacturing Systems
Product layout: Layout that uses standardized processing
operations to achieve smooth, fast, high-volume flow
Workers
6
Out 10 9 8 7
High rate of output
Low unit cost
Labor specialization
Low material handling cost
High utilization of labor and equipment
Established routing and scheduling
Routine accounting, purchasing and inventory control
Creates boring, repetitive jobs
Poorly skilled workers may not maintain equipment or
quality of output
Fairly inflexible to changes in volume
Highly inclined to shutdowns
Needs preventive maintenance
Individual incentive plans are impractical
Process layouts: Layouts that can handle various
processing requirements
The layouts feature departments or other functional
groupings in which similar kinds of activities are performed
Examples: Machine shops usually have separate
departments for milling, grinding, drilling, and so on
Different products may present quite different processing
requirements and sequences of operations
Milling
Assembly
& Test Grinding
Drilling Plating
0.1 min. 0.7 min. 1.0 min. 0.5 min. 0.2 min.
CT = cycle time