0. Manufacturing Process LayoutD G A
Receiving and
Shipping
Assembly
Painting Department
Lathe Department
Milling
Department
Drilling Department
Grinding P

1. Process (Job Shop) Layouts
Equipment that perform similar processes are grouped together
Used when the operations system must handle a wide variety of products in relatively small volumes (i.e., flexibility is necessary)

2. Characteristics of Process Layouts
General-purpose equipment is used
Changeover is rapid
Material flow is intermittent
Material handling equipment is flexible
Operators are highly skilled
more

3. Characteristics of Process Layouts
Technical supervision is required
Planning, scheduling and controlling functions are challenging
Production time is relatively long
In-process inventory is relatively high

4. A Product Layout In
Out

5. Product (Assembly Line) Layouts
Operations are arranged in the sequence required to make the product
Used when the operations system must handle a narrow variety of products in relatively high volumes
Operations and personnel are dedicated to producing one or a small number of products

6. Characteristics of Product Layouts
Special-purpose equipment are used
Changeover is expensive and lengthy
Material flow approaches continuous
Material handling equipment is fixed
Operators need not be as skilled
. . . more

7. Characteristics of Product Layouts
Little direct supervision is required
Planning, scheduling and controlling functions are relatively straight-forward
Production time for a unit is relatively short
In-process inventory is relatively low

8. Comparison of Product and Process Layouts
Description
Type of process
Product
Demand
Volume
Equipment
Sequential arrangement of activities
Continuous, mass production, mainly assembly
Standardized, made to stock
Stable
High
Special purpose
Functional grouping of activities
Intermittent, job shop, batch production, mainly fabrication
Varied, made to order
Fluctuating
Low
General purpose

9. Comparison of Product and Process Layouts
Workers
Inventory
Storage space
Material handling
Aisles
Scheduling
Layout decision
Goal
Advantage
Limited skills
Low in-process, high finished goods
Small
Fixed path (conveyor)
Narrow
Line balancing
In-l,ine, U-type
Equalize work at each station
Efficiency
Varied skills
High in-process, low finished goods
Large
Variable path (forklift)
Wide
Dynamic
Functional
Minimize material handling cost
Flexibility

10. Cellular Manufacturing (CM) Layouts
Grouping of machines in cells
Each cell results in the production of particular part family.
Similar parts are identified and grouped together.
Similarity can be either in shape,size or in manufacturing process
Operations required to produce a particular family (group) of parts are arranged in the sequence required to make that family
Used when the operations system must handle a moderate variety of products in moderate volumes

11. Part families Part families with similarity in manufacturing process
Part families with similarity in shape

12. Original Process LayoutB
Raw materials
Assembly 1 2 3 4 5 6 7 8 9 10 11 12

13. Part Routing Matrix Machines Parts 1 2 3 4 5 6 7 8 9 10 11 12
A x x x x x
B x x x x
C x x x
D x x x x x
E x x x
F x x x
G x x x x
H x x x
Figure 5.8

14. Reordered Routing Matrix
Machines
Parts
A x x x x x
D x x x x x
F x x x
C x x x
G x x x x
B x x x x
H x x x
E x x x

15. Revised Cellular Layout3 6 9
Assembly 1 2 4 8 10 5 7 11 12
A B C
Raw materials
Cell 1
Cell 2
Cell 3

16. Automated Manufacturing Cell
Source: J. T. Black, “Cellular Manufacturing Systems Reduce Setup Time, Make Small Lot
Production Economical.” Industrial Engineering (November 1983)

17. Characteristics of CM Relative to Process Layouts
Equipment can be less general-purpose
Material handling costs are reduced
Training periods for operators are shortened
In-process inventory is lower
Parts can be made faster and shipped more quickly
Equipment can be less special-purpose
Changeovers are simplified
Production is easier to automate

18. Flexible Manufacturing Systems (FMS)
FMS consists of numerous programmable machine tools connected by an automated material handling system and controlled by a common computer network
FMS combines flexibility with efficiency
FMS layouts differ based on
variety of parts that the system can process
size of parts processed
average processing time required for part completion

19. Full-Blown FMS