1. Manufacturing Systems Facilities and Technology
Volume and Variety
Facility Layout
Technology
Compiled by:
Alex J. Ruiz-Torres, Ph.D.
From information developed by many.

2. Mfg Facilities and Technology
The type of product and the customer requirements dictates the technologies used and the type of facility.
Key characteristics
Variety: will it produce a few/ standardized products or many different types (even customized products).
Volume: relative measure of how much will the system produce (5 computers per day, 2,000 computers per day)

3. Mfg Technology and Facilities
Volume and variety are directly associated with the level of automation and standardization of the production process. This drives the efficiency and cost.
An artisan making wooden saints - makes 1 every week
One hundred artisans in a factory following the same process and with the same equipment in a), would make 100 units per week.
One hundred artisans using a specialized process (for example, the best artisans at making the head, make the head, the best ones at carving the arms ….), plus they use some automated machines, could make 200 units per week.

4. Volume and Variety The Product-Process Matrix Volume Variety
Few product types made in high volume;
specialized equipment;
significant automation;
highly efficient;
low cost per unit.
Continuous
Process/ Assembly Line
High
Volume
Batch/Flow Shop
The middle….
Low
Job Shop
Many product types each
produced in very small amounts
(sometimes only one);
general purpose equipment;
little or no automation;
low efficiency;
high cost per unit.
Low
High
Variety

5. Volume and Variety Example: Cakes. Assembly line
mass produced in specialized lines
inflexible
huge volumes
typically lowest cost per slice of cake.
Image Sources:
Youtube.com, everychina.com

6. Volume and Variety Batch production smaller quantities
more versions/ types of products, even seasonals
semi dedicated production lines
higher cost than previous case.

7. Volume and Variety Job shop make to order (MTO)
no specialized equipment
each cake is a new project
typically highest cost per slice of cake.

8. Facility Layout
Facility layout relates to the placement of departments, workgroups within departments, workstations, machines, and stock-holding points within a facility.

9. Facility Layout Two basic forms
Product based: the facility is organized around the flow of one or a few products. Facilities with assembly lines.
Process based: the facility is organized around equipment and groups dedicated to processes.
Different products may have different flows across the layout.
product flow
line 1
stores
shipping
line 2
line 3 5
stores
cut/ sand 4 1 3
painting
testing
shipping 2
welding
electronic assembly

10. Facility Layout
The layout has an effect in many measures of performance:
Movement time - longer distances = more time moving.
Number of touches which is related to labor costs.
Inventory locations often dictate inventory quantities and therefore costs.
Poor layouts result in materials or people getting lost / temporarily disappearing.

11. Manufacturing Technology
Equipment and information technologies.
Equipment tech to make, assemble, test, and pack the products.
Information tech to support decision making.
Technology replaces operators.
Technology allows for faster and higher quality production.

12. Manufacturing Technology
Computer controlled production equipment is prevalent in some industries such as automobile and electronic production.
Drawbacks:
Sometimes it limits flexibility (equipment is difficult to modify),
Requires significant investments and know how.

13. Manufacturing Technology
3D manufacturing: process to make a product by adding material using computer controlled systems.
This technology replaces traditional processes as cutting, milling, molding,…