1. Methods, Standards, and Work Design
Products and Facilities
Chapter 3
Methods, Standards, and Work Design
11th Edition
Niebel/Freivalds

2. Concurrent Engineering Defined
the simultaneous development of project design functions
open and interactive communication existing among all team members for the purposes of:
reducing time to market,
decreasing cost, and
improving quality and reliability

3. Design for Manufacturing and Assembly
Greatest improvements related to DFMA arise from simplification of the product by reducing the number of separate parts:
1. During the operation of the product, does the part move relative to all other parts already assembled?
2. Must the part be of a different material or be isolated from other parts already assembled?
3. Must the part be separate from all other parts to allow the disassembly of the product for adjustment or maintenance?

4. Types of Processes Conversion - changing iron ore into steel
Fabrication - making car bumpers from plastic
Assembly - assembling a car
Testing - computer boards - not a fundamental process

5. Process Flow Structures
Job shop - small batches of a large number of different products
printing, machine shop, tool & die
Batch shop - standardized job shop, products produced in batches
clothing
Assembly Line - parts move from station to station at a controlled rate
microwaves, cars
Continuous Flow - continuous versus discrete flow
beer, paint

6. IV. Continuous Flow III. Assembly Line II. Batch I. Job Shop Low
Exhibit 5.10
IV.
Continuous
Flow
III.
Assembly
Line
II.
Batch I.
Job
Shop
Low
Volume,
One of a
Kind
Multiple
Products,
Volume
Few
Major
Higher
High
Standard-
ization
Commercial
Printer
French Restaurant
Heavy
Equipment
Coffee Shop
Automobile
Burger King
Sugar
Refinery
Flexibility (High)
Unit Cost (High)
Flexibility (Low)
Unit Cost (Low)

7. Basic Production Layout Formats
Process Layout
Product Layout
Group Technology (Cellular) Layout
Fixed-Position Layout

8. Flow Through Systems

9. Process-Oriented Layout
Design places departments with large flows of material or people together
Dept. areas have similar processes
e.g., All x-ray machines in same area
Used with process-focused processes
Examples
Hospitals
Machine shops
© 1995 Corel Corp.

10. Process-Oriented Layout Floor Plan
Office
Table Saws
© 1995 Corel Corp.
Drill Presses
Tool Room
© 1995 Corel Corp.

11. Product-Oriented Layout
Facility organized around product
Design minimizes line imbalance
Delay between work stations
Types: Fabrication line; assembly line
Examples
Auto assembly line
Brewery
Paper mfg.
© T/Maker Co.

12. Product-Oriented Layout Floor Plan1 3
Operations 4 5 2
Belt Conveyor
Office

13. Cellular Layout - Group Technology (Work Cells)
Special case of process-oriented layout
Consists of different machines brought together to make a product
Group Technology Benefits:
Better human relations
Improved operator expertise
Less in-process inventory and material handling
Faster production setup

14. Work Cell Floor Plan
Saws
Drills
Office
Work Cell
Tool Room

15. Fixed-Position Layout
Design is for stationary project
Workers & equipment come to site
Complicating factors
Limited space at site
Changing material needs
Examples
Ship building
Highway construction
© Corel Corp.
© Corel Corp.
© 1995 Corel Corp.

16. Fixed Position Layout
Question: What are our primary considerations for a fixed position layout?
Answer: Arranging materials and equipment concentrically around the production point in their order of use.