Process Selection and Facility Layout 6 Process Selection and Facility Layout

Learning Objectives Explain the strategic importance of process selection. Explain the influence that process selection has on an organization. Describe the basic processing types. Discuss automated approaches to processing. Explain the need for management of technology.

Learning Objectives List some reasons for redesign of layouts. Describe the basic layout types. List the main advantages and disadvantages of product layouts and process layouts. Solve simple line-balancing problems. Develop simple process layouts.

Introduction Process selection Major implications Deciding on the way production of goods or services will be organized Major implications Capacity planning Layout of facilities Equipment Design of work systems

Process Selection and System Design Figure 6.1 Forecasting Product and Service Design Technological Change Capacity Planning Process Selection Facilities and Equipment Layout Work Design

Process Strategy Key aspects of process strategy Capital intensive – equipment/labor Process flexibility Technology Adjust to changes Design Volume technology

Technology Technology: The application of scientific discoveries to the development and improvement of products and services and operations processes. Technology innovation: The discovery and development of new or improved products, services, or processes for producing or providing them.

Kinds of Technology Operations management is primarily concerned with three kinds of technology: Product and service technology Process technology Information technology All three have a major impact on: Costs Productivity Competitiveness

Technology Competitive Advantage Innovations in Products and services Cell phones PDAs Wireless computing Processing technology Increasing productivity Increasing quality Lowering costs

Technology Acquisition Technology can have benefits but … Technology risks include: What technology will and will not do Technical issues Economic issues Initial costs, space, cash flow, maintenance Consultants and/or skilled employees Integration cost, time resources Training, safety, job loss

Process Selection Variety Flexibility Volume How much What degree Expected output Batch Job Shop Repetitive Continuous

Process Types Job shop Batch Repetitive/assembly line Continuous Small scale Batch Moderate volume Repetitive/assembly line High volumes of standardized goods or services Continuous Very high volumes of non-discrete goods

Product and Service Processes Figure 6.2 Process Type Job Shop Appliance repair Emergency room Ineffective Batch Commercial baking Classroom Lecture Repetitive Automotive assembly Automatic carwash Continuous (flow) Steel Production Water purification

Product – Process Matrix Figure 6.2 (cont’d) Dimension Job variety Very High Moderate Low Very low Process flexibility Unit cost Volume of output High

Product and Process Profiling Process selection can involve substantial investment in Equipment Layout of facilities Product profiling: Linking key product or service requirements to process capabilities Key dimensions Range of products or services Expected order sizes Pricing strategies Expected schedule changes Order winning requirements

Automation Automation: Machinery that has sensing and control devices that enables it to operate Fixed automation Programmable automation

Automation Computer-aided design and manufacturing systems (CAD/CAM) Numerically controlled (NC) machines Robot Manufacturing cell Flexible manufacturing systems(FMS) Computer-integrated manufacturing (CIM)

Facilities Layout Layout: the configuration of departments, work centers, and equipment, with particular emphasis on movement of work (customers or materials) through the system Product layouts Process layouts Fixed-Position layout Combination layouts

Objective of Layout Design Facilitate attainment of product or service quality Use workers and space efficiently Avoid bottlenecks Minimize unnecessary material handling costs Eliminate unnecessary movement of workers or materials Minimize production time or customer service time Design for safety

Importance of Layout Decisions Requires substantial investments of money and effort Involves long-term commitments Has significant impact on cost and efficiency of short-term operations

The Need for Layout Decisions 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 Design (Cont’d) Changes in environmental or other legal requirements Changes in volume of output or mix of products Changes in methods and equipment Morale problems

Basic Layout Types Product layouts Process layouts Fixed-Position layout Combination layouts

Basic Layout Types Product layout Process layout Fixed Position 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

Product Layout Figure 6.4 Raw materials or customer Station 1 Station 2 Station 3 Station 4 Finished item Material and/or labor Material and/or labor Material and/or labor Material and/or labor Used for Repetitive or Continuous Processing

Advantages of Product 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

Disadvantages of Product 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

A U-Shaped Production Line Figure 6.6 1 2 3 4 5 6 7 8 9 10 In Out Workers

Used for Intermittent processing Job Shop or Batch Processes Process Layout Figure 6.7 Process Layout (functional) Dept. A Dept. B Dept. D Dept. C Dept. F Dept. E Used for Intermittent processing Job Shop or Batch Processes

Used for Repetitive Processing Repetitive or Continuous Processes Product Layout Figure 6.7 (cont’d) Product Layout (sequential) Work Station 1 Station 2 Station 3 Used for Repetitive Processing Repetitive or Continuous Processes

Advantages of Process Layouts Can handle a variety of processing requirements Not particularly vulnerable to equipment failures Equipment used is less costly Possible to use individual incentive plans

Disadvantages of Process Layouts 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

Fixed Position Layouts Fixed Position Layout: Layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed. Nature of the product dictates this type of layout Weight Size Bulk Large construction projects

Cellular Layouts Cellular Production Group Technology 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

Functional vs. Cellular Layouts Table 6.3 Dimension Functional Cellular Number of moves between departments many few Travel distances longer shorter Travel paths variable fixed Job waiting times greater Throughput time higher lower Amount of work in process Supervision difficulty Scheduling complexity Equipment utilization

Service Layouts Warehouse and storage layouts Retail layouts Office layouts Service layouts must be aesthetically pleasing as well as functional

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.

Cycle Time Cycle time is the maximum time allowed at each workstation to complete its set of tasks on a unit.

Determine Maximum Output

Determine the Minimum Number of Workstations Required

Precedence Diagram a b c d e Figure 6.11 Precedence diagram: Tool used in line balancing to display elemental tasks and sequence requirements A Simple Precedence Diagram a b c d e 0.1 min. 0.7 min. 1.0 min. 0.5 min. 0.2 min.

Example 1: Assembly Line Balancing Arrange tasks shown in Figure 6.10 into three workstations. Use a cycle time of 1.0 minute Assign tasks in order of the most number of followers

Example 1 Solution Workstation Time Remaining Eligible Assign Task Revised Time Remaining Station Idle Time 1 1.0 0.9 0.2 a, c c none a - 2 b 0.0 3 0.5 0.3 d e

Calculate Percent Idle Time Efficiency = 1 – Percent idle time

Line Balancing Rules Some Heuristic (intuitive) Rules: 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 task’s time and the times of all following tasks.

Example 2 0.2 0.2 0.3 a b e 0.8 0.6 c d f g h 1.0 0.4 0.3

Solution to Example 2 a b e f d g h c Station 1 Station 2 Station 3

Bottleneck Workstation 1 min. 2 min. 30/hr. Bottleneck

Parallel Workstations 1 min. 2 min. 60/hr. 30/hr. Parallel Workstations

Designing Process Layouts Information Requirements: List of departments Projection of work flows Distance between locations Amount of money to be invested List of special considerations Location of key utilities

Example 3: Interdepartmental Work Flows for Assigned Departments Figure 6.13 1 3 2 30 170 100 A B C

PowerPoint Author’s note: The following three slides are not in the 9e text, but I like to use them for alternate examples.

Process Layout - work travels to dedicated process centers Milling Assembly & Test Grinding Drilling Plating

Functional Layout Gear cutting Mill Drill Lathes Grind Heat treat Assembly 111 333 222 444 1111 2222 3333 333333333 44444 333333 22222

Cellular Manufacturing Layout -1111 222222222 - 2222 Assembly 3333333333 - 3333 44444444444444 - 4444 Lathe Mill Drill Heat treat Gear cut Grind