Nothing Special   »   [go: up one dir, main page]
Scribd Logo
Upload

Welcome to Scribd!

  • 82 views

    Process Selection and Layout

    Uploaded by

    Satish RAj
    The document discusses different types of process flows - continuous, connected, disconnected, and jumbled - and how the choice of process depends on factors like volume and variety of products manufactured. It describes qualitative and quantitative approaches to designing process layouts based on criteria like closeness between resources and total transportation costs. Product layout design uses line balancing techniques to identify the minimum resources needed to meet production rates and their optimal arrangement.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Process Selection and Layout

    Uploaded by

    Satish RAj
    82 views19 pages
    The document discusses different types of process flows - continuous, connected, disconnected, and jumbled - and how the choice of process depends on factors like volume and variety of products manufactured. It describes qualitative and quantitative approaches to designing process layouts based on criteria like closeness between resources and total transportation costs. Product layout design uses line balancing techniques to identify the minimum resources needed to meet production rates and their optimal arrangement.

    Original Description:

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document discusses different types of process flows - continuous, connected, disconnected, and jumbled - and how the choice of process depends on factors like volume and variety of products manufactured. It describes qualitative and quantitative approaches to designing process layouts based on criteria like closeness between resources and total transportation costs. Product layout design uses line balancing techniques to identify the minimum resources needed to meet production rates and their optimal arrangement.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    82 views19 pages

    Process Selection and Layout

    Uploaded by

    Satish RAj
    The document discusses different types of process flows - continuous, connected, disconnected, and jumbled - and how the choice of process depends on factors like volume and variety of products manufactured. It describes qualitative and quantitative approaches to designing process layouts based on criteria like closeness between resources and total transportation costs. Product layout design uses line balancing techniques to identify the minimum resources needed to meet production rates and their optimal arrangement.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 19

    Process Selection and Facility Layout

    Module 1 Wrap-up
    Session 8
    Process Flows
    • Design of process is largely dependent on the type of flow of
    products in an operating system (firm/business unit)
    • Different types of flows occur in firms
    – Continuous flow
    – Connected flow (Assembly line)
    – Disconnected flow (Batch shop)
    – Jumbled flow (Job shop)
    • What are the flows corresponding to each of the cases we
    discussed?
    Process choice
    • What factors affect the choice of a process?
    – Volume of the product manufactured
    – Variety of the product manufactured
    High Volume Mid-volume Low Volume
    Low Variety Mid-variety High Variety

    Petrochemicals, Motor Manufacturing Power plants


    Automobile Pharmaceuticals Aircraft manufacturing
    FMCGs White Goods Bridges & Large
    Consumer non-durables Consumer Durables Constructions
    Where do our cases Fall?

    Volume

    Variety

    Variation in Demand

    Visibility
    Is there a one-to-one mapping between
    volume/variety of products and choice of process?
    Product – Process Matrix
    Jumbled
    Flow Satellite Launch
    Opportunity Costs
    (Job Shop) Vehicle

    Disconnected
    Line Flow Machine Tools
    (Batch Shop)

    Connected Line
    Flow (Assembly Automotive
    Line) Components line

    Continuous Out of Pocket Costs


    Flow
    Oil Refinery

    Low Volume High Volume


    Multiple Products Few Major Products
    Low Standardisation High Standardisation
    Low Volume Higher Volume
    One of a kind Commodity Products

    Source: Adapted from Hayes and Wheelright (1979).


    Process design for operations

    Flow Characteristics Continuous Intermittent Jumbled

    Product High Volume, Low Variety Medium Volume, Medium High Variety, Low Volume
    Characteristics Variety
    Examples of Process Industry, Mass Batch production in Process Project Organisations, Tool
    production systems production systems in and discrete manufacturing Rooms, General purpose
    discrete manufacturing fabricators
    Issues of Flow Balancing, Manufacturing system and Capacity Estimation,
    importance Maintenance, Capacity layout design, Changeover Scheduling, Production
    utilization and management, Capacity Control, Cost estimation
    debottlenecking, Vertical planning and estimation
    integration
    Layout Design and Planning
    • Deals with the physical arrangement of various resources
    (machines and labor)
    • Optimal design helps in improving the performance of the firm
    – Jobs/People in manufacturing setup have to travel less
    – Customers spend less time in queues and in system in service shops
    – Direct effect/Indirect effect on Cost, Quality and Responsiveness
    – Example: Donner Case - Reduction in movement time between stations!
    Types of Layout
    • Process/Functional Layout
    • Product Layout
    • Group Technology (GT) Layout (Cellular Manufacturing)
    • Fixed Position Layout

    • Is there a dominant layout that can be followed for a type of


    volume-variety and flow?
    Process Layout
    L – Lathe
    D – Drilling
    Product A M- Machining
    L L L L D D
    Product B G - Grinding
    D D
    Product C L L L L
    D D
    M M

    G G G
    M M
    Product Layout
    L – Lathe
    D – Drilling
    Product A L D M G M- Machining
    G - Grinding

    Product B L D L G

    Product C L D M L G
    Group Technology Layout
    Cell 1 Cell 2

    L M D M D L

    D L G G D L

    L D L D

    M L G L M
    Cell 4 Cell 3

    https://www.youtube.com/watch?v=Ynhp8Wi2qwM
    Fixed Position Layout
    Performance Measures
    Performance Measure Basis for measurement

    Distance travelled by jobs in the shop floor Kg - Metres of job movement for each product

    Space utilization index Minimum space required to actual space utilised

    Material Handling costs Rupees per month


    Lead time of the processes Hours per average product
    Investment in work-in-progress Rupees per month
    Number and quantum of inter-departmental
    Inter-departmental moves
    moves
    Utilisation of the resources Percent to total capacity

    Number of job cards and control documents


    Ease of production control
    generated; Size of the progress chasing staff

    Number of times the responsibility for the job


    Number of ownership changes
    changes hands
    Design of Process Layouts
    • Qualitative Method
    – Links criteria to the closeness required between a pair of resources
    • Quantitative Method
    – Uses quantitative performance measures for assessing the impact of layout design
    – Seeks to arrive at the best layout design by optimizing on this performance measure
    • Performance evaluation models using computer simulation techniques
    Design of Process layout-Qualitative Approach

    Department 1
    Value Closeness O
    A Absolutely necessary Department 2 A
    U I
    E Especially Important Department 3 O E
    I Important A X A
    O Ordinary closeness OK Department 4 U U
    U O
    U Unimportant Department 5 O
    X Undesirable O
    Department 6
    Design of Process Layout – Quantitative Approach
    • Cij = Cost per unit of transporting a unit distance from department “i” to department
    “j”
    • Fij = Inter-departmental flow between department “i” and department “j”
    • Dij = Distance between department “i” and department “j”
    • n = Number of departments to be laid out
    • The total cost of the plan is given by:
    n n
    TC   F D C
    i 1 j 1
    ij ij ij

    • If this is the objective function (minimizing the total cost of the plan), can we model a
    constrained optimization problem?
    Design of Product Layout
    • Several Mass Production Systems are in operation today
    – Various sub-assemblies (activities/resources) in a mass producer need to be
    configured to match the production rate
    – The final assembly stations need to have the required number of resources at each
    station to meet the targeted demand
    • A product layout design
    – Seeks to identify the minimum number of resources required to meet a targeted
    production rate and the order in which these resources are to be arranged
    – Technique employed for designing product layout is known as line balancing
    Module Wrap-up

    You might also like