ISE3214 Facilities Planning and

Material Handling

Production Flow Systems

Class Overview and ISE3214 Introduction 1

ACILITY DESIGN
ANALYSIS/TOOLS

Schedule
Design

2
GATHERING SCHEDULE INFORMATION

Schedule design impacts

Machine selection
Number of machines
Number of shifts
Number of employees
Space requirements
Storage equipment
.

Class Overview and ISE3214 Introduction 3

Material Handling, Chp. 3

MAJOR TYPES OF PRODUCTION

SYSTEMS

Class Overview and ISE3214 Introduction 4

WHERE DOES ALL THIS LEAD TO?

Building blocks for facility planning & design

Layout
Location
Material Handling
Storage, etc.

Integrating all parts together can determine

what type of facility is being designed and
lead to conclusions on the layout/flow

Class Overview and ISE3214 Introduction 5

MATERIAL FLOW SYSTEMS

Arguably, the most important building

blocks for a facility are flows -- the flows of
goods, materials, energy, information,
energy, and/or people.

The flow of people tends to dictate the design

of offices. Similarly, the flow of material tends
to dictate the design of manufacturing and
assembly facilities.

The principal of minimizing total flow

represents theClass
work simplification
Overview and ISE3214 Introduction approach 6
The work simplification approach to material flow

1. Eliminating flow by planning for the delivery of

materials, information, or people directly to the
point of ultimate use and eliminating intermediate
steps
2. Minimizing multiple flows by planning for the flow
between two consecutive points of use to take
place in as few movements as possible, preferably
one
3. Combining flows and operations wherever
possible by planning for the movement of
materials, information, or people to be combined
with a processing step.

Class Overview and ISE3214 Introduction 7

The principle of minimizing the cost of flow

1. Eliminate unnecessary movements of

material by reducing the number of
manufacturing steps
2. Minimize manual handling by minimizing
travel distances
3. Eliminate manual handling by mechanizing
or automating flow
4. Minimize material handling by reducing the
flow density through containerization.

Class Overview and ISE3214 Introduction 8

Flow Patterns: Top-Down Approach

Flow BETWEEN departments

Flow WITHIN departments

Flow WITHIN workstations

Class Overview and ISE3214 Introduction 9

Flow BETWEEN Departments

Often used to evaluate overall flow in a

facility
An important consideration in flow between
the departments:
Location of pick up and delivery for each
station

Entrance and exit positions are often fixed

and has great impact on the design

Class Overview and ISE3214 Introduction 10

Flow Patterns: Top-Down Approach

Flow BETWEEN departments

Flow WITHIN departments

Flow WITHIN workstations

Class Overview and ISE3214 Introduction 11

Mechanized Flow within Product and Process Departments

Flow patterns within

product and process
departments tend to
Be:
(a) line flow,
(b) spine flow,
(c) loop flow, and
(d) tree flow

Class Overview and ISE3214 Introduction 12

Flow within Product and Process Departments

Spine flow:

Class Overview and ISE3214 Introduction 13

Flow within Product and Process Departments

Loop flow:

Class Overview and ISE3214 Introduction 14

Flow within Product and Process Departments

Tree flow:

Class Overview and ISE3214 Introduction 15

Flow WITHIN Departments (Product, GT layouts)

End-to-end Front-to-front
Back-to-back

Circular
Odd-angle
One operator per WS Multiple WS per operator
What about flow WITHIN Process departments?
Class Overview and ISE3214 Introduction 16
Process Departments

In a process department,
similar or identical
machines are grouped in
the same department. A
minimal amount of flow
occurs between
workstations. Flow
occurs between aisles
and workstations. Flow
patterns are dictated by
the orientation of
workstations to aisles.
Class Overview and ISE3214 Introduction 17
Flow Patterns: Top-Down Approach

Flow BETWEEN departments

Flow WITHIN departments

Flow WITHIN workstations

Class Overview and ISE3214 Introduction 18

Flow WITHIN a Workstation

Ergonomic
considerations
Work design

Motion studies

Flow should be simultaneous, symmetrical, natural,

rhythmical, and habitual
Class Overview and ISE3214 Introduction 19
DEPARTMENTAL PLANNING

Depending on the product mix and production

volume mix among products, production
planning departments can be classified as a)
product, b) fixed materials location, c)
product family (or group technology), or d)
process planning departments.

Class Overview and ISE3214 Introduction 20

TYPES OF PRODUCTS/SYSTEMS

21
FIXED PRODUCT LAYOUT

People and equipment go to the product

Combine all workstations with the staging
area
Product not moved
Equipment moved to product
Low equipment utilization

Class Overview and ISE3214 Introduction 22

FIXED PRODUCT LAYOUT (cont.)

Lathe Press Grind

W
S a
t r
o e
r h
a o
g u
e s
e
Weld Paint Assembly

Equipment is brought to the location of the item being

constructed or manufactured, e.g., building an office building, an
airplane, or a ship.

Class Overview and ISE3214 Introduction 23

FIXED PRODUCT LAYOUT (cont.)

Advantages
1. Material movement is reduced.
2. Promotes job enlargement by allowing individuals or
teams to perform the whole job.
3.Continuity of operations and responsibility results
from team.
4. Highly flexible; can accommodate changes in
product design, product mix, and product volume.
5.Independence of production centers allowing
scheduling to achieve minimum total production
time.
Class Overview and ISE3214 Introduction 24
FIXED PRODUCT LAYOUT (cont.)

Limitations
1. Increased movement of personnel and
equipment.
2. Equipment duplication may occur.
3. Higher skill requirements for personnel.
4. General supervision required.
5. Cumbersome and costly positioning
of material and machinery.
6. Low equipment utilization.
Class Overview and ISE3214 Introduction 25
PRODUCT LAYOUT

Flow line, operations performed in serial

High output volume, low variety
Low material handling costs
Not flexible but can be automated

Class Overview and ISE3214 Introduction 26

PENCIL MANUFACTURING
http://www.youtube.com/watch?v=KS2zQXq7AFY

27
PRODUCT LAYOUT

Lathe Drill Grind Drill

A W
S s a
t Press Bend Drill s r
o e e
r m h
a b o
g Mill Drill u
l
e y s
e
Lathe Lathe Drill

Facility designed for direct flow for individual

products (i.e., assembly line), e.g., flow shop.

Class Overview and ISE3214 Introduction 28

PRODUCT LAYOUT (cont.)

Advantages
1. Since the layout corresponds to the sequence of
operations, smooth and logical flow lines result.
2. Since the work from one process is fed directly into the
next, small in-process inventories result.
3.Total production time per unit is short.
4. Since the machines are located so as to minimize
distances between consecutive operations, material
handling is reduced.
5.Little skill is usually required by operators at the production
line; hence, training is simple, short, and inexpensive.
6. Simple production planning control systems are possible.
7. Less space is occupied by work in transit and for
temporary storage.

Class Overview and ISE3214 Introduction 29

PRODUCT LAYOUT (cont.)

Limitations
1. A breakdown of one machine may lead to a
complete stoppage of the line that follows that
machine.
2.Since the layout is determined by the product, a
change in product design may require major
alternations in the layout.
3. The pace of production is determined by the
slowest machine.
4. Supervision is general, rather than specialized.
5. Comparatively high investment is required, as
identical machines (a few not fully utilized) are
sometimes distributed along the line.
Class Overview and ISE3214 Introduction 30
PROCESS LAYOUT

Organize departments based on process/equip.

Products may use different tooling, high skill
level
Highly customized work
Low productivity
High work-in-process inventory
Long cycle times
Complex planning
Workers must be experts
http://www.youtube.com/watch?v=V-9eMmfThD
8
Class Overview and ISE3214 Introduction 31
EXAMPLE PROCESS LAYOUT

Milling
Lathe Department 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
Grinding Painting Department
Department
L L
Receiving and
A A A
Shipping Assembly

32
PROCESS LAYOUT (cont.)

Advantages
1. Better utilization of machines can result;
consequently, fewer machines are required.
2. A high degree of flexibility exists relative to
equipment or man power allocation for specific
tasks.
3.Comparatively low investment in machines is
required.
4. The diversity of tasks offers a more interesting
and satisfying occupation for the operator.
5.Specialized supervision is possible.

Class Overview and ISE3214 Introduction 33

PROCESS LAYOUT (cont.)

Limitations
1. Since longer flow lines usually exist, material
handling is more expensive.
2. Production planning and control systems are more
involved.
3. Total production time is usually longer.
4. Comparatively large amounts of in-process
inventory result.
5. Space and capital are tied up by work in process.
6. Because of the diversity of the jobs in specialized
departments, higher grades of skill are required.

Class Overview and ISE3214 Introduction 34

GROUP TECHNOLOGY

Mix between product and process layouts

Products and machines are grouped into
families based on analytical methods
Form cells that can be operated by less
operators
Analytical analysis at beginning
Low WIP
Low congestion
Faster response and easier scheduling

Class Overview and ISE3214 Introduction 35

GROUP TECHNOLOGY (cont.)

Lathe Drill Grind Assembly

W
S a
t Mill Assembly Weld Paint r
o e
r h
a o
g Press Lathe Drill Press Assembly u
e s
e
Grind Drill Assembly Drill Grind

A delicate mix between a process and a product layout. Usually

dedicate some machines to specific products and place the rest in
a process department. An example of a GT layout is a batch shop.

Class Overview and ISE3214 Introduction 36

GROUP LAYOUT (cont.)

Advantages
1. Increased machine utilization.
2. Team attitude and job enlargement tend to
occur.
3.Compromise between product layout and
process layout, with associated advantages.
4. Supports the use of general purpose
equipment.
5. Shorter travel distances and smoother flow
lines than for process layout.
Class Overview and ISE3214 Introduction 37
GROUP TECHNOLOGY (cont.)

Limitations
1. General and specialized supervision required.
2.Higher skill levels required of employees than for
product layout.
3. Compromise between product layout and
process layout, with associated limitations.
4. Depends on balanced material flow through the
cell; otherwise, buffers and work-in-process
storage are required.
5. Lower machine utilization than for process
layout.
Class Overview and ISE3214 Introduction 38
CELL
LAYOUTS

39
LAYOUT SUMMARY
Characteristic Product Process Group Fixed Position

Throughput Time

W.I.P.

Skill Level Choice Mixed

Product Flexibility

Demand Flexibility

Machine Utilization

Worker Utilization

Unit Production Cost

Low High Medium Medium-High Medium-Low

= bad

= indifferent

= good
40
HYBRID LAYOUT

Combination of the layouts previously discussed.

A sample hybrid layout that has characteristics of group, process and
product layout is shown in the following figure.
A combination of group layout in manufacturing cells, product layout in
assembly area, and process layout in the general machining and finishing
section is used.

TM DM TM TM

z
BM TM TM

Class Overview and ISE3214 Introduction 41

JOB SHOP vs. FLOW SHOP

Job Shop: a production system that manufactures a high variety of

products with a relatively low volume (for each product), generally
small batch sizes.
- setups between different products
- pooled resources (i.e., use the same machine for many products)

Flow Shop: a production system that manufacturers a small number

of products with a relatively high volume (for each product),
generally large batch sizes.
- continuous processing (i.e., not many setups)
- dedicated machines to each product

Hybrid/Batch Shop: a production system that manufactures

products using a mix of job shop and flow shop designs.
- dedicate some machines; the rest are job-shop.
- most Production Systems are Batch Shop or Hybrid Shop; pure
Class Overview and ISE3214 Introduction 42
job shops or pure flow shops are not prevalent.