Chap006_Process Selection & Facility Layout
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Transcript of Chap006_Process Selection & Facility Layout
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6-1 Process Selection and Facility Layout
CHAPTER
6
Process Selectionand Facility Layout
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6-2 Process Selection and Facility Layout
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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6-3 Process Selection and Facility Layout
Forecasting
Product and
Service Design
Technological
Change
Capacity
Planning
ProcessSelection
Facilities and
Equipment
Layout
Work
Design
Figure 6.1
Process Selection and System Design
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6-4 Process Selection and Facility Layout
Key aspects of process strategy Capital intensive equipment/labor
Process flexibility
Adjust to changes
Design
Volume
technology
Process Strategy
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6-5 Process Selection and Facility Layout
Job shop Small scale
Batch
Moderate volume
Repetitive/assembly line
High volumes of standardized goods or services
Continuous
Very high volumes of non-discrete goods
Process Types
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6-6 Process Selection and Facility Layout
Process Type
Job Shop Appliance repairEmergency
room
Not
feasible
Batch Commercial
bakeryClassroom
Lecture
Repetitive Automotiveassembly
Automatic
carwash
Continuous
(flow)
Not
feasible
Oil refinery
Water purification
Figure 6.2
ProductProcess Matrix
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6-7 Process Selection and Facility Layout
Dimension
Job variety Very High Moderate Low Very low
Process
flexibility
Very High Moderate Low Very low
Unit cost Very High Moderate Low Very low
Volume of
output
Very High Low High Very low
Figure 6.2 (contd)
ProductProcess Matrix
6 8 P S l ti d F ilit L t
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6-8 Process Selection and Facility Layout
Automation: Machinery that has sensing andcontrol devices that enables it to operate
Fixed automation
Programmable automation
Automation
6 9 P S l ti d F ilit L t
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6-9 Process Selection and Facility Layout
Computer-aided design andmanufacturing systems (CAD/CAM)
Numerically controlled (NC) machines
Robot Manufacturing cell
Flexible manufacturing systems(FMS)
Computer-integrated manufacturing (CIM)
Automation
6 10 P S l ti d F ilit L t
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6-10 Process Selection and Facility Layout
Layout: the configuration of departments,work centers, and equipment, with particular
emphasis on movement of work (customers
or materials) through the system
Facilities Layout
6 11 P S l ti d F ilit L t
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6-11 Process Selection and Facility Layout
Requires substantial investments of moneyand effort
Involves long-term commitments
Has significant impact on cost and efficiencyof short-term operations
Importance of Layout Decisions
6 12 P S l ti d F ilit L t
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6-12 Process Selection and Facility Layout
Inefficient operations
For Example:
High Cost
Bottlenecks
Changes in the design
of products or services
The introduction of new
products or services
Accidents
Safety hazards
The Need for Layout Decisions
6 13 Process Selection and Facility Layout
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6-13 Process Selection and Facility Layout
Changes inenvironmental
or other legal
requirements
Changes in volume of
output or mix of
products
Changes in methodsand equipment
Morale problems
The Need for Layout Design (Contd)
6 14 Process Selection and Facility Layout
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6-14 Process Selection and Facility Layout
Product layouts
Process layouts
Fixed-Position layout
Combination layouts
Basic Layout Types
6 15 Process Selection and Facility Layout
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6-15 Process Selection and Facility Layout
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, andequipment are moved as needed
Basic Layout Types
6 16 Process Selection and Facility Layout
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6-16 Process Selection and Facility Layout
Raw
materials
or customer
Finished
item
Station
2
Station
3
Station
4
Material
and/or
labor
Station
1
Material
and/or
labor
Material
and/or
labor
Material
and/or
labor
Used for Repetitive or Continuous Processing
Figure 6.4
Product Layout
6 17 Process Selection and Facility Layout
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6-17 Process Selection and Facility Layout
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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6-18 Process Selection and Facility Layout
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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6-19 Process Selection and Facility Layout
Can handle a variety of processingrequirements
Not particularly vulnerable to equipment
failures Equipment used is less costly
Possible to use individual incentive plans
Advantages of Process Layouts
6-20 Process Selection and Facility Layout
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6 20 Process Selection and Facility Layout
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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6 21 Process Selection and Facility Layout
Line Balancing is the process of assigning
tasks to workstations in such a way that
the workstations have approximately
equal time requirements.
Design Product Layouts: Line Balancing
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6 22 Process Selection and Facility Layout
Cycle time is the maximum time
allowed at each workstation tocomplete its set of tasks on a unit.
Cycle Time
6-23 Process Selection and Facility Layout
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6 23 Process Selection and Facility Layout
Percent idle time =Idle time per cycle
(N)(CT)
Efficiency = 1 Percent idle time
Calculate Percent Idle Time
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6 24 Process Selection and Facility Layout
Assign tasks in order of most following
tasks.
Count the number of tasks that follow
Assign tasks in order of greatest positional
weight.
Positional weight is the sum of each tasks
time and the times of all following tasks.
Some Heuristic (intuitive) Rules:
Line Balancing Rules
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6 25 Process Selection and Facility Layout
Information Requirements:1. List of departments
2. Projection of work flows
3. Distance between locations
4. Amount of money to be invested
5. List of special considerations
6. Location of key utilities
Designing Process Layouts