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Manufacturing Process Layout

Milling Department. Lathe Department. Drilling Department. M. M. D. D. D. D. L. L. M. M. D. D. D. D. L. L. G. G. G. P. L. L. G. G. G. P. L. L. Painting Department. Grinding Department. L. L. A. A. A. Receiving and Shipping. Assembly.

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Manufacturing Process Layout

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  1. Milling Department Lathe Department Drilling Department M M D D D D L L M M D D D D L L G G G P L L G G G P L L Painting Department Grinding Department L L A A A Receiving and Shipping Assembly Manufacturing Process Layout

  2. 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)

  3. 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

  4. 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

  5. In Out A Product Layout

  6. 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

  7. 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

  8. 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

  9. Description Type of process Product Demand Volume Equipment Comparison of Productand Process Layouts Product Process • 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

  10. Workers Inventory Storage space Material handling Aisles Scheduling Layout decision Goal Advantage Comparison of Productand Process Layouts Product Process • 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

  11. 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

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

  13. Assembly 4 7 9 6 8 5 12 2 10 3 1 11 A B C Raw materials Original Process Layout

  14. 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 Part Routing Matrix Figure 5.8

  15. Machines Parts 1 2 4 8 10 3 6 9 5 7 11 12 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 Reordered Routing Matrix

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

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

  18. Characteristics of CMRelative 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

  19. 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

  20. Full-Blown FMS

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