Process and Material Flow

Analysis
Chapter 3
 Data requirement for layout
decisions
• Frequency of trips or flow of material or
some other measure of interaction
between departments
• Shape and size of departments
• Floor space available
• Location restrictions for departments, if
any
• Adjacency requirements between pairs of
departments, if any
Flow pattern at 800-acre Nissan
plant in Smyrna, TN
Possible flow patterns
Dendrite flow pattern
Spine flow pattern
 Five types of layout
• Product layout
• Process layout
• Fixed-position layout
• Group-technology layout
• Hybrid layout
Types of Departments/Layouts
Volume
High
Product
Department

Product
Layout Product
Medium Family
Department
Fixed Location Process
Layout Layout
Group Technology
Fixed Materials Layout Process
Location
Department
Department
Low

Low Medium High Variety

Source: John S. Usher class notes

Product layout
 Product Layouts
Product A Department

D D M G P D A
Receiving Department

Shipping Department
Product B Department

L L M M D G P A

Product C Department

L L L G G P A

Source: John S. Usher class notes

 Process layout

DM DM
TM TM

DM
TM TM

VMM VMM BM BM
 The 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

Source: John S. Usher class notes

Flow of Materials in Process Layouts
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

Source: Russell & Taylor, 2007

 Group technology layout

DM
VMM
TM DM

TM BM
BM TM

VMM DM TM
Product Family (Cellular) Layout
G
G G D D D
L L
D M G
D L
L
P
M G D L
Rotational
L Parts

P
Cell M D L

Rectangular G L
L M Parts
Cell A Special
A Department

Receiving and
Shipping

Source: John S. Usher class notes

 A Manufacturing Cell
HM

Direction of part movement within cell

VM
Paths of three
workers moving Worker 3
within cell VM

Material L
movement

Key: Worker 2
G
S = Saw
L = Lathe L
HM = Horizontal milling machine
VM = Vertical milling machine Final
inspection
G = Grinder

Finished
S Worker 1 part

In Out
Source: John S. Usher class notes
Product Family (Cellular) Layout
• Promote flow with little WIP
• Facilitate workers staffing multiple machines
• U-shaped cells
• Maximum visibility
• Minimum walking
• Flexible in number of workers
• Facilitates monitoring of work entering and leaving cell
• Workers can conveniently cooperate to smooth flow and address
problems

17
 Layout for JIT
Cellular Layout:
– Proximity for flow control, material handling, floating labor, etc.
– May require duplication of machinery
– logical cells

Advanced Material Handling:

– Avoid large transfer batches
– Close coordination of physically
separate operations
Inbound Stock Outbound Stock

18
 Project (Fixed-Position) Layout
G G D D D
L
G

L
G
Storage

Storage
L
A
L
M P A

Receiving and
Shipping

Source: John S. Usher class notes

 Hybrid layout

TM TM VMM BM

DM
TM TM
 Hybrid Layouts
• Combination of the layouts 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

BM TM TM
 General Characteristics
Characteris Produ Process Product Project
tic ct Family
Throughput Time Low High Low Medium
Work in process Low High Low Medium
Skill Level Choice High Med-High Mixed
Product Flexibility Low High Med-High High
Demand Flexibility Medium High Medium Medium
Mach Utilization High Med-Low Medium-High Medium
Worker Utilization High High High Medium
Reliability Can be High High Medium
low
Unit production Low High Low High
cost
Automated Manufacturing Cell

Source: John S. Usher class notes

Flexible Manufacturing Systems
 Automated machining operations, tool changers
 Automated material handling, computer control
 Designed around size of parts processed & average
processing time for parts
 Can process wide variety of items quickly
 Very few large systems exist
Progressive layout – all parts same route
Closed loop – larger variety, alternative routes
Ladder layout – two machines work on same part
Open field layout – most complex
FLOW PROCESS CHART
Flow process chart
Subject Charted TB03100 Face Panel Chart No. 112XAG

Drawing No. Part No. Chart of Method Present

Chart Begins Receiving Charted By N.L.

Chart Ends Steel Dept. Date Feb. 5/90 Sheet 1 of 1

Dist. Time Chart Oper Dept M/C # of How Process Description

(ft) Symbol ID ID ID pieces moved
.02 1 A1 S&R 100 Truck Received material 0.022 wcs (51" x 102")
220 .02 1 H2 MF1 100 Forklift To crane bay area
2 WIP1 100 Stored temporarily
20 .02 2 H2 MF1 100 Conveyor To hydra shear
.01 1 M1 MF1 HS1 100 Cut to length (front panel)
50 .02 3 H3 MF2 13G 95 Forklift To machine #13G (100 ton press) or Komatsu
142 (machine 142) or to HYMAC 101 (7" & over neck)
.01 2 M2 MF2 101 95 Necking operation (punch hole)
160 .03 4 H3 MF2 95 Forklift To machine # 136
.03 3 M2 MF2 136 95 Punch holes
240 .01 5 H1 MF3 95 Forklift To machine #155 or machine #104 or machine #111
.05 4 M2 MF3 155 95 Braking operation
260 .01 6 H1 WIP2 94 AGV To marshalling area
3 S&R 94 Temporary storage
150 .01 7 H3 WIP3 94 AGV To steel dept.
Summary
Event Total Time Distance
 Operations 4
Inspections — — —
Transportations 8 (min.) 1100 ft.
 Storages 3
Delays
 Flow diagram
C

L
VT
R

S D

M
 Qualitative flow data
• Relationship chart
– A absolutely necessary
– E especially important
– I important
– O ordinary
– U unimportant
– X undesirable
• Percentages of A. E, I, O, U and X ratings
– A 2-5%
– E 3-10%
– I 5-15%
– O 10-25%
– U 25-60%
– X depends
 Qualitative flow data
• Color coding relationships
–A Red
–E Orange or Yellow
–I Green
–O Blue
–U Uncolored
–X Brown
 Sample relationship chart

Code Reason
1. Form
A/1
2. Trim I/2 1 Bulky material
E/2 O/2
3. Treat U U 2 Ease of supervision
X/3 U
4. Assembly E/2
U 3 Safety
5. Pack and Ship
 Quantitative flow data
• From-to frequency of trips matrix

Dept Dept Dept Dept Dept Det 6

1 2 3 4 5
Dept 1 - 12 3 3
Dept 2 21 -
Dept 3 4 5 - 8 8 8
Dept 4 - 4 4
Dept 5 1 2 2 15 - 19
Dept 6 4 9 7 19 -
 Quantitative flow data
• Frequency of trips between departments matrix

Dept Dept Dept Dept Dept Dept

1 2 3 4 5 6
Dept 1 - 33 7 3 1 4
Dept 2 33 - 5 2 9
Dept 3 7 5 - 8 10 8
Dept 4 3 8 - 19 11
Dept 5 1 2 10 19 - 38
Dept 6 4 9 8 11 38 -
 Distance Measures
• Euclidean
• Squared Euclidean
• Rectilinear
• Tchebychev
• Aisle distance
• Adjacency
• Shortest Path
Euclidean, Squared Euclidean,
Rectilinear and Tchebychev
Facility j

(xj,yj)

Facility i
|yi-yj|

(xi,yi) |xi-xj|
Aisle Distance, Adjacency and
Shortest Path
d
Facility j

Facility i
Facility k

b
 Layout evaluation criteria

 c
i j
ij f ij d ij
• cij cost of moving a unit load of material
unit distance between departments i and j
• fij number of loads or trips required
between departments i and j
• dij distance between departments i and j
 Tools for presenting layout design
• Drawings
• Templates
• Three-dimensional physical models
• CAD models