CHAPTER 3: FLOW SYSTEM, ACTIVITY RELATIONSHIPS,
The communications that coordinate the resources
AND SPACE REQUIREMENTS
3.1 INTRODUCTION
 Three important considerations in determining the
requirements of a facility:
1. Flow systems – depends on production and
transfer lot sizes, unit load sizes, material handling
systems, layout arrangement, and building
configuration.
2. Activity relationships – between machines and
departments
3. Space requirements – a function of lot sizes,
storage systems, production equipment type and
size, layout arrangement, building configuration,
housekeeping and organization policies, material
handling equipment, etc.
 The facilities planning process is an iterative process
 The facilities team and planner needs to interact
not only with product, process, and schedule
designers but also with top management to
identify issues and alternatives strategies to
consider in the analysis.
3.2 FLOW SYSTEMS
 Movement of goods, materials, energy, info, and/ people.
 Discrete flow process – discrete items move thru
the flow process.
o Can be categorized according to the stages of
supply, manufacture, and distribution cycle.
 Material management system
 Material flow system
 Physical distribution system
o The three (3) categories may be combined
into one overall flow system and is referred to
as logistics system
o The activities associated with the
materials management system and
physical distribution system are often
referred to as supply chain management
system.
 Continuous flow process – the products
continuously move thru successive production
states.
 A flow process may be described in terms of:
a. The subject of flow – the item to be processed.
b. The resources that bring about flow – processing
and transporting facilities required to accomplish
the required flow.
c.
- coordinate the resources include the procedures
that facilitate the management of the flow process.
3.2.1 Material Management System
 The flow process being considered is the flow of materials
into a manufacturing facility.
3.2.1 Materials Flow System
 Is the flow of materials, parts and supplies within a
manufacturing facility is to be the subject of the flow
process.
3.2.3 Physical Distribution System
 The flow of products from a manufacturing facility to be
the subject of the flow.
3.3 MATERIAL FLOW SYSTEM
 Define the overall flow environment within which material
movement takes place.
 The principle of minimizing total flow represents the
work simplification approach to material flow.
 Minimizing the cost of flow.
3.3.1 Flow within Workstations
 Simultaneous vs. Symmetrical
 Simultaneous flow – implies the coordinated use of
hands, arms, and feet. Should begin and end their
motion together.
 Symmetrical flow – results from the coordination of
movements about the center of the body. (E.g. the
left and right hand and arms should be working in
coordination)
 Natural flow patterns – the basis for rhythmical and
habitual flow patterns.
3.3.2 Flow within Departments
 Is dependent on the type of department.
3.3.2.1 Flow within a Product Department
 The processing is sequential with minimal or no
backtracking.
 Front-to-front patterns – used when one operator
works on two workstations
 Circular flow patterns – used when one operator
works on more than two workstations.
3.3.2.2 Flow within a Process Department
 Similar or identical machines are grouped in the same
department.
 A minimal amount of flow should occur between
workstations (aisles) within departments.
 Diagonal flow patterns – typically used in conjunction
with one-way aisles.