Process Selection and Facility Layout
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Transcript of Process Selection and Facility Layout
![Page 1: Process Selection and Facility Layout](https://reader036.fdocuments.us/reader036/viewer/2022062422/568134c6550346895d9bebc1/html5/thumbnails/1.jpg)
Process Selection and Facility Layout
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• 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
Introduction
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Forecasting
Product andService Design
TechnologicalChange
CapacityPlanning
ProcessSelection
Facilities andEquipment
Layout
WorkDesign
Process Selection and System DesignInputs Outputs
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Key aspects of process strategy– Capital intensive – equipment/labor– Process flexibility– Adjust to changes
– Design– Volume– Technology
Process Strategy
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• Variety– How much
• Flexibility– What degree
• Volume – Expected output Job Shop
Batch
Repetitive
Continuous
Process Selection
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Process types
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• Job shop– Small scale, wide variety of goods
• Batch– Moderate volume, flexible
• Repetitive or assembly line– High volumes of standardized goods or services
• Continuous– Very high volumes of non-discrete goods
• Projects– Nonroutine work, uniqe set ob objectives, limited
timeframe and resources
Process types and volume
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Product – Process Matrix
The diagonal of the matrix represents the ideal choice of processing system for a given sets of circumstances.
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Functions/activities affected by process choice
Job variety, process flexibility, unit cost
Volume
Limited(not ongoing)
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Product and service life cycles
• Alongside the life cycle the sales and with it the producion volume can change.
• So managers must be aware of the change in the optimal processing system. (the necessity of change is highly dependent on the particular good or service)
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Product/Service Profilig
• Linking key product or service requirements to process capavilities.
• Design the process with taking into consideration the following:– Range of products/services– Expected order size– Pricing– Expected frequency of changes in schedules etc.– Order-winning requirements– …
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Sustainable production
• Non-polluting• Conserving natural resources & energy• Economically efficient• Safe and healthful for workers, communities
and consumers• Socially and creaqtively rewarding for workers
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• Automation: Machinery that has sensing and control devices that enables it to operate– Fixed automation– Programmable automation
Automation of production and services
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Advantages of automation
• Low variability in performance and quality• Machines do not
– get bored or distracted– go out on strike or ask for higher wages– lower variable costs
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Disadvantages
• Higher initial (investment) cost and • Higher fixed costs• Lower felxibility• Higher skills needed• Lower morale of human workforce• Need for standardisation
– Products– Processes– Equipment and materials etc.
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• Computer-aided design and manufacturing systems (CAD/CAM)
• Numerically controlled (NC) machines • Computerized numerical control (CNC)• Direct numerical control (DNC)
• Robot: mechanical arm + power supply + controller• Manufacturing cell• Flexible manufacturing systems (FMS)• Computer-integrated manufacturing (CIM)
Automation
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• Layout: the configuration of departments, work centers, and equipment, with particular emphasis on movement of work (customers or materials) through the system
Facilities Layout
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• Requires substantial investments of money and effort
• Involves long-term commitments• Has significant impact on cost and
efficiency of short-term operations
Importance of Layout Decisions
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The Need for Layout Decisions
• Inefficient operations• High (variable) Cost• Bottlenecks
• Changes in the design of products or services• The introduction of new products or services• Safety• Changes in environmental or other legal
requirements• Changes in volume of output or mix of products• Changes in methods and equipment• Morale problems
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Objectives of facility layout
Main: smooth flow of work, material and information
Supporting objectives:
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• Product layouts
• Process layouts
• Fixed-Position layout
Hybrid types:
• Combination layouts
Basic Layout Types
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• 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
Basic Layout Types
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Used for Repetitive or Continuous Processing
Product Layout
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• 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
Advantages of Product Layout
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• 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
Disadvantages of Product Layout
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A U-Shaped Production Line
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Advantages/disadvantages of U-shaped lines
• Shorter distances for workers & machines
• Permits communication thus facilitates teamwork
• More flexible work assignments
• Optimal is the facility has the same entry and exit point
• If lines are highly automated, there is no need for communication and travel
• If entry points are on the opposite side as exit points
• Noise and contamination factors are increased in the U-shape
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Dept. A
Dept. B Dept. D
Dept. C
Dept. F
Dept. E
Used for Intermittent processingJob Shop or Batch
Process Layout(functional)
Process Layout
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Work Station 1
Work Station 2
Work Station 3
Product Layout(sequential)
Used for Repetitive ProcessingRepetitive or Continuous
Product Layout
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• Can handle a variety of processing requirements
• Not particularly vulnerable to equipment failures
• Equipment used is less costly• Possible to use individual incentive plans
Advantages of Process Layouts
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• 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
Disadvantages of Process Layouts
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Fixed-position layouts
• The product or project remains stationary and workers, materials, and equipment are moved as needed.
• If weight, size, bulk, or some other factor makes it undesirable or extremely difficult to move the product.
• E.g. firefighting, road-building, home-building, drilling for oil etc.
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• 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– Makes cellular production much more effective
Cellular Layouts
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Traditional process layout
Cellular layout
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Dimension Functional CellularNumber of moves between departments
many few
Travel distances longer shorter
Travel paths variable fixed
Job waiting times greater shorter
Throughput time higher lower
Amount of work in process
higher lower
Supervision difficulty higher lower
Scheduling complexity higher lower
Equipment utilization lower higher
Functional vs. Cellular Layouts
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• Use of flexible manufacturing systems
Service layouts• Warehouse and storage layouts
– Minimizing movement & picking time and cost
• Retail layouts– Presence & influence of customers
• Office layouts:– Information is computerized, image of openness
Other Solutions & Service Layouts
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Design Product Layouts: Line Balancing
Line Balancing is the process of assigning tasks to workstations in such a way that the workstations have approximately equal time requirements.This way the idle time will be minimized, utilization will be maximized
Specialzation: dividing work into elematal tasks that can be performed quickly and routinely
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Cycle Time
Cycle time is the maximum time allowed at each workstation to complete its set of tasks on a unit.
tmax < Cycle time < ∑t
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Determine the Minimum Number of Workstations Required
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A diagram that shows elemental tasks and their precedence requirements.
A Simple Precedence Diagrama b
c d e
0.1 min.
0.7 min.
1.0 min.
0.5 min. 0.2 min.
Precedence Diagram
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Assume that the desired output is 480 units per day. The facility is workint 8 hours a day. The elemental tasks and their connections are shown in the previous slide.
• Calculate the cycle time.• Calculate the minimum number of workstations.• Arrange the tasks into these workstations in the
order of the greatest number of following tasks.
Example 1: Assembly Line Balancing
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WorkstationTimeRemaining Eligible
AssignTask
RevisedTime Remaining
StationIdle Time
1 1.0
0.9
0.2
a, c *
c **
none***
a
c
-
0.9
0.2
0.2
2 1.0 b b 0.0 0.0
3 1.0
0.5
0.3
d
e
-
d
e
-
0.5
0.3 0.3
Total: 0.5
Example 1 Solution
* Tasks that have no predecessors.** b is not eligible, because it needs more time than than the remaining.*** Every available task needs more time than 0.2.
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Efficiency = 1 – Percent idle time
Calculate Percent Idle Time and efficiency
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Line balancing procedure
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• Assign tasks in order of most following tasks.– Count the number of tasks that follow
• Assign tasks in order of task time.
• Assign tasks in order of greatest positional weight. – Positional weight is the sum of each task’s time
and the times of all following tasks.
Line Balancing Heuristics
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Example 2
Working day is 8 hours and the desired output rate is 400 units per day.
Draw the precedence diagram.Compute the cycle time & the minimum number of workstations required.Assign tasks to workstations according to the greatest number of following tasks. Tiebreaker: longest processing time goes first.Calculate Percent idle time & efficiency.
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Other approaches
• Paralell workstations• Cross-train workers (dynamic line balancing)• Mixed model line
(more product on the same line)
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1 min.2 min.1 min.1 min. 30/hr. 30/hr. 30/hr. 30/hr.
1 min.
1 min.
1 min.1 min. 60/hr.
30/hr. 30/hr.
60/hr.
1 min.
30/hr.30/hr.
Bottleneck
Parallel Workstations
Parallel Workstations
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Thank you for your attention