05_03_2015_Process Selection and Facility Layout

1 IRWIN

a Times Mirror Higher Education Group, Inc. company, 1996

Process Selection and Facility Layout

CHAPTER

6

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Questions for Process Analysis

and Design

Is the process designed to achieve competitive advantage in terms of differentiation, response, or low cost?

Does the process eliminate steps that do not add value?

Does the process maximize customer value as perceived by the customer?

Will the process win/keep orders?

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Process Selection and System Design

Forecasting

Product and service design

Capacity planning

Facilities and Equipment

Layout

Work design

Process selection

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Types of Processes

Job Shops - Small runs/variety Batch Processing - Similar groups Repetitive/Assembly - Discrete goods Continuous Processing - Bulk/no variety Projects - Nonroutine jobs

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Repetitive Production

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Continuous Production

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Product-Process Lifecycle Matrix

Flexibility-Quality Dependability-Cost

Continuous Flow

Assembly Line

Batch

Job Shop

Low Volume One of a

Kind

Multiple Products,

Low Volume

Few Major

Products, Higher Volume

High Volume,

High Standard-

ization

Commercial Printer

Heavy Equipment

Automobile Assembly

Sugar Refinery

Flexibility- Quality

Dependability Cost

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Automation/Technology Decisions Automation -- The substitution of technology for

human activity Key Question -- How does technology fit

strategically (appropriateness)? Four other questions managers must ask--

What will new technology do and not do? What will new technology require? What will new technology cost (total/life cycle)? How certain are we of the answers above?

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Automation Numerically controlled machines

(NC) Robotics, Vision, Automatic ID Computer-aided design and

manufacturing systems (CAD/CAM) Flexible manufacturing systems Computer-integrated

manufacturing (CIM)

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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

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The Need for Layout Designs (Contd) Changes in environmental or other legal requirements

Changes in volume of output or mix of

products

Changes in methods and equipment

Morale problems

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Basic Layout Types

Product Layouts Process Layouts Fixed-Position Combination Layouts Cellular Layouts

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Basic Layout Types Product Layout

Uses standardized processing operations to achieve smooth, sequential, rapid, high-volume flow (production/assembly lines)

Process Layout By Department or Function. Flexibly handles

varied processing requirements Fixed Position Layout

Product or project stationary, and workers, materials, and equipment are moved to site as needed

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Cellular Layouts

Cellular Manufacturing

Group Technology

Flexible Manufacturing Systems

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Cellular Layouts

Cellular Manufacturing Machines grouped into cells to make

families of items with similar processing requirements

Group Technology Grouping items into part families based

on design or manufacturing similarities

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a Times Mirror Higher Education Group, Inc. company, 1996 Ch 6 - 33 1998 by Prentice-Hall Inc Russell/Taylor Oper Mgt 2/e

Flexible Manufacturing System

Parts Finished goods

Load Unload

Computer control room

Terminal

Machine Machine

Tools

Conveyor

Pallet

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a Times Mirror Higher Education Group, Inc. company, 1996 Ch 6 - 37 1998 by Prentice-Hall Inc Russell/Taylor Oper Mgt 2/e

Components Of CIM

CIM

Product design

Manufacture

Process planning

Systems management

Robotics FMS NC/CNC/ DNC Cells

and centers Automated inspection

AGV, ASRS

JIT/ kanban

DSS/ES/ AI

LAN, TOP, satellites

TQM

Bar codes, EDI

MRP

GT CAE CAD IGES, PDES, DMIS

DFM

Cellular manufacturing

MAP, STEP

CAD/CAM

CAPP

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Other Service Layouts

Warehouse and Storage Frequency of use, item correlation

Retail Customer needs, traffic pattern/flow

Office Less flow dependent

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Tools for Process Design

Flow Diagrams Process Charts Time-Function/Process Mapping Service Blueprints

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Production Process Flow Diagram

Shipping

Customer

Customer sales representative

take order

Prepress Department (Prepare printing

plates and negatives)

Printing Department

Collating Department

Gluing, binding, stapling, labeling

Polywrap Department

Purchasing (order inks, paper, other

supplies) Vendors

Receiving

Warehousing (ink, paper, etc.)

Accounting

Information flow Material flow

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Time Function Map

Customer

Sales

Production control

Plant A

Warehouse

Plant B

Transport

Order Product

Process Order

Print

Extrude

Receive product

Wait

Move

Wait Wait Wait

Move

Ord

er

Ord

er

WIP

WIP

WIP

WIP

Pro

duct

Prod

uct

Prod

uct

12 days 1 day 1 day 1 day 1 day 13 days 4 days 10 days 9 days

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SUBJECT: Request tool purchase

Dist (ft) Time (min) Symbol Description

lo D Write order

o On desk 75 o D To buyer

n D Examine = Operation; = Transport; o = Inspect; D = Delay; = Storage

Process Chart Example

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Service Blueprinting

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05_03_2015_Process Selection and Facility Layout