Process and Material Flow Analysis Chapter 3
Data requirement for layout decisions Frequency of trips or flow of material or some other measure of interaction between departments Shape and size of departments Floor space available Location restrictions for departments, if any Adjacency requirements between pairs of departments, if any
Flow pattern at 800-acre Nissan plant in Smyrna, TN
Possible flow patterns
Dendrite flow pattern
Spine flow pattern
Five types of layout Product layout Process layout Fixed-position layout Group-technology layout Hybrid layout
Types of Departments/Layouts Volume High Medium Low Low Medium High Variety Product Department Fixed Materials Location Department Process Department Product Family Department Product Layout Fixed Location Layout Group Technology Layout Process Layout
Product layout
Product Layouts L L LL LM M M DD D DG G G GA A Product C Department Product A Department P P P Product B Department A Shipping Department Receiving Department
Process layout
The Process Layout L L L L L L L L L L M M M M D D D D D D D D G G G G G G A AA Receiving and Shipping Assembly Painting Department Lathe Department Milling Department Drilling Department Grinding Department P P
Flow of Materials in Process Layouts L L L L L L L L L L M M M M D D D D D D D D G G G G G G A AA Receiving and Shipping Assembly Painting Department Lathe Department Milling Department Drilling Department Grinding Department P P
Group technology layout
Product Family (Cellular) Layout L L L L L L L L L M M M M DD D D D D D G G GG G G A A Receiving and Shipping Special Department Rotational Parts Cell P P Rectangular Parts Cell Source: John S. Usher class notes
A Manufacturing Cell Key: S= Saw L= Lathe HM= Horizontal milling machine VM= Vertical milling machine G= Grinder Paths of three workers moving within cell Material movement In Out Worker 1 Worker 2 Worker 3 Direction of part movement within cell S L HM VM G L Final inspection Finished part Source: John S. Usher class notes
Project (Fixed-Position) Layout L L L L M DDD G GG G A A Receiving and Shipping P Storage Source: John S. Usher class notes
Hybrid layout
Hybrid Layouts Combination of the layouts discussed. A sample hybrid layout that has characteristics of group, process and product layout is shown in the following figure. A combination of group layout in manufacturing cells, product layout in assembly area, and process layout in the general machining and finishing section is used. TM DM BM
General Characteristics CharacteristicsProductProcessProduct Family Project Throughput TimeLowHighLowMedium Work in processLowHighLowMedium Skill LevelChoiceHighMed-HighMedium Product FlexibilityLowHighMed-HighHigh Demand FlexibilityMediumHighMedium Mach UtilizationHighMed-LowMedium-HighMedium Worker UtilizationHigh Medium ReliabilityCan be low High Medium Unit production cost LowHighLowHigh
Exercise – What Type of Layout? Assembly Plant ___________ Meijers___________ Suburban Hospital___________ International Airport ___________ Restaurant ___________ Boeing Aircraft___________
Automated Manufacturing Cell
Flexible Manufacturing Systems Automated machining operations, tool changers Automated material handling, computer control Designed around size of parts processed & average processing time for parts Can process wide variety of items quickly Very few large systems exist Progressive layout – all parts same route Closed loop – larger variety, alternative routes Ladder layout – two machines work on same part Open field layout – most complex