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    Process Selection and Facility Layout

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    Achim Braganca
    Process selection and facility layout have major implications for capacity planning, equipment design, and work system organization. Key aspects of process strategy include balancing capital vs labor needs, flexibility, and ability to adapt to changes. Process types include job shop, batch, repetitive/assembly line, and continuous. Automation levels range from fixed automation to computer integrated manufacturing. Facility layout configurations include product, process, and combination layouts. Layout decisions require substantial investment and impact cost, efficiency, and operations.

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    Process Selection and Facility Layout

    Uploaded by

    Achim Braganca
    40 views33 pages
    Process selection and facility layout have major implications for capacity planning, equipment design, and work system organization. Key aspects of process strategy include balancing capital vs labor needs, flexibility, and ability to adapt to changes. Process types include job shop, batch, repetitive/assembly line, and continuous. Automation levels range from fixed automation to computer integrated manufacturing. Facility layout configurations include product, process, and combination layouts. Layout decisions require substantial investment and impact cost, efficiency, and operations.

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    Process selection and facility layout have major implications for capacity planning, equipment design, and work system organization. Key aspects of process strategy include balancing capital vs labor needs, flexibility, and ability to adapt to changes. Process types include job shop, batch, repetitive/assembly line, and continuous. Automation levels range from fixed automation to computer integrated manufacturing. Facility layout configurations include product, process, and combination layouts. Layout decisions require substantial investment and impact cost, efficiency, and operations.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    40 views33 pages

    Process Selection and Facility Layout

    Uploaded by

    Achim Braganca
    Process selection and facility layout have major implications for capacity planning, equipment design, and work system organization. Key aspects of process strategy include balancing capital vs labor needs, flexibility, and ability to adapt to changes. Process types include job shop, batch, repetitive/assembly line, and continuous. Automation levels range from fixed automation to computer integrated manufacturing. Facility layout configurations include product, process, and combination layouts. Layout decisions require substantial investment and impact cost, efficiency, and operations.

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    Process Selection

    and Facility Layout


    Introduction
    • Process selection
    • Deciding on the way production of goods or services will be organized
    • Major implications
    • Capacity planning
    • Layout of facilities
    • Equipment
    • Design of work systems
    Process Selection and System Design
    Facilities and
    Forecasting Capacity Equipment
    Planning

    Product and Layout


    Service Design

    Process
    Technological Selection Work
    Change Design
    Process Strategy

    • Key aspects of process strategy


    – Capital intensive – equipment/labor
    – Process flexibility
    – Adjust to changes
    – Design
    – Volume
    – technology
    Process Selection
    • Variety Batch
    • How much
    • Flexibility Job Shop Repetitive
    • What degree
    • Volume
    • Expected output Continuous
    Process Types
    • Job shop
    • Small scale
    • Batch
    • Moderate volume
    • Repetitive/assembly line
    • High volumes of standardized goods or services
    • Continuous
    • Very high volumes of non-discrete goods
    Automation
    • Automation: Machinery that has sensing and control devices that
    enables it to operate
    • Fixed automation
    • Programmable automation
    Automation
    • Computer-aided design and
    manufacturing systems (CAD/CAM)
    • Numerically controlled (NC) machines
    • Robot
    • Manufacturing cell
    • Flexible manufacturing systems(FMS)
    • Computer-integrated manufacturing (CIM)
    Facilities Layout
    • Layout: the configuration of departments, work centers, and
    equipment, with particular emphasis on movement of work
    (customers or materials) through the system
    Importance of Layout Decisions
    • Requires substantial investments of money and effort
    • Involves long-term commitments
    • Has significant impact on cost and efficiency of short-term operations
    The Need for Layout Decisions

    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
    The Need for Layout Design (Cont’d)

    Changes in
    environmental Changes in volume of
    or other legal output or mix of
    requirements products

    Morale problems
    Changes in methods
    and equipment
    Basic Layout Types
    • Product layouts
    • Process layouts
    • Fixed-Position layout
    • Combination layouts
    Basic Layout Types
    • Product layout
    • Layout that uses standardized processing operations to achieve smooth,
    rapid, high-volume flow
    • Process layout
    • Layout that can handle varied processing requirements
    • Fixed Position layout
    • Layout in which the product or project remains stationary, and workers,
    materials, and equipment are moved as needed
    Product Layout

    Raw Finished
    Station Station
    Station Station
    Station Station
    Station
    materials 1 22 33 44 item
    or customer
    Material Material Material Material

    and/or and/or and/or and/or


    labor labor labor labor

    Used for Repetitive or Continuous Processing


    Advantages of Product Layout
    • High rate of output
    • Low unit cost
    • Labor specialization
    • Low material handling cost
    • High utilization of labor and equipment
    • Established routing and scheduling
    • Routing accounting and purchasing
    Disadvantages of Product Layout
    • Creates dull, repetitive jobs
    • Poorly skilled workers may not maintain equipment or quality of
    output
    • Fairly inflexible to changes in volume
    • Highly susceptible to shutdowns
    • Needs preventive maintenance
    • Individual incentive plans are impractical
    A U-Shaped Production Line

    In 1 2 3 4

    Workers

    Out 10 9 8 7
    Process Layout
    Process Layout
    (functional)

    Dept. A Dept. C Dept. E

    Dept. B Dept. D Dept. F

    Used for Intermittent processing


    Job Shop or Batch
    Product Layout
    Product Layout
    (sequential)

    Work Work Work


    Station 1 Station 2 Station 3

    Used for Repetitive Processing


    Repetitive or Continuous
    Advantages of Process Layouts
    • Can handle a variety of processing requirements
    • Not particularly vulnerable to equipment failures
    • Equipment used is less costly
    • Possible to use individual incentive plans
    Disadvantages of Process Layouts
    • In-process inventory costs can be high
    • Challenging routing and scheduling
    • Equipment utilization rates are low
    • Material handling slow and inefficient
    • Complexities often reduce span of supervision
    • Special attention for each product or customer
    • Accounting and purchasing are more involved
    Fixed-Position Layouts
    • Layout in which the product or project remains stationary, and
    workers, materials, and equipment are moved as needed.
    Cellular Layouts
    • Cellular Production
    • Layout in which machines are grouped into a cell that can process items that
    have similar processing requirements
    • Group Technology
    • The grouping into part families of items with similar design or manufacturing
    characteristics
    Other Service Layouts
    • Warehouse and storage layouts
    • Retail layouts
    • Office layouts
    Designing Process Layouts
    Information Requirements:
    1. List of departments
    2. Projection of work flows
    3. Distance between locations
    4. Amount of money to be invested
    5. List of special considerations
    6. Location of key utilities

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