CHAPTER 3: PROCESS LAYOUT

2

End of chapter Student should be able to :
Organize the process layout in manufacturing

Discuss the Group Technology

Expose the concept of Flexible manufacturing System (FMS)

The role of computer Integrated Manufacturing (CIM)

Planning activities for the
preparation of industrial
equipment including labor,
equipment, space saving,
material handling equipment
from service and design of the
building to reach the most
efficient level of production

1 •TexLt Hayeroeut can achieve the desired objectives
2 •TexUt Hseereeffective work time
3 •TexRt Hederuece production costs and increase the amount of output
4 T•exCt aHnerbee easily modified according to time and circumstance

Text Here

Layout planning is planning that involves decisions about the physical
arrangement of economic activity centres needed by a facility’s various
processes.

Layout plans translate the broader decisions about the competitive
priorities, process strategy, quality, and capacity of its processes into
actual physical arrangements.

Economic activity centre : anything that consumes space : a person or
group of people , a customer reception area, a teller window, a machine a
workstation a department, an aisle, or a storage room

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can make decision must be addressed llaayyoouut tinicnlucdleud?e ?
regarding physical HHoowwmuchmsupcahce ansdpcaapcaecity and
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Facility layout can be defined as the process by which the placement of
department, workgroup within department, workstation, machines and stock
holding points within a facility are determined

The basic objective of the layout decision is to
ensure a smooth flow of work, material, people,
and information through the system.

This process requires the following inputs :

Specification of objectives of the lean
system in term of output and flexibility
Estimation of product or service demand
on the system
Processing requirements in terms of number
of operations and amount of flow between
department and work centers
Space requirement for element in the layout

Space availability within the facility itself

▪ The flow (number of The BEST location for each
moves to and from all department where best
departments means Maximizing flow ,
which Minimizing costs.
▪ The cost of moving from
one department to
another

▪ The existing or planned
physical layout of plant

Altering a layout can effort an
organization and how well its competitive
priorities in the following ways :

Increasing customer satisfaction and sales
retail store
Facilitating the flow of materials and
information
Increasing the efficient utilization of
labor and equipment

Reducing hazards to workers

Improving employee morale and commutation

A layout that organizes resources An arrangement in which service or
(employees) and equipment by manufacturing site is fixed in place
function rather than by service or employees along with their equipment,
product come to the site to do their work

A layout in which workstation or An arrangement in which some portions
department are arranged in a linear path. of the facility have a flexible –flow and

other have a line flow layout



Lathe Department Milling M Drilling Department D
LL Department DDD D

M DDD

MM

LL

LL GG GP
GG
LL GP
LL Grinding Painting Department
Department
Services Process Layout Receiving and AAA
Shipping Assembly
Women’s
lingerie Housewares Manufacturing Process
Layout

Shoes

Women’s Cosmetics and Children’s
dresses jewelry department

Women’s Entry and Men’s
sportswear display area department

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In
Out

The major concern in a product layout is balancing the assembly line so
that no one workstation becomes a bottleneck and holds up the flow of

work through the line.

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GROUP TECHNOLOGY

DEFINITION GROUP TECHNOLOGY

Group technology(GT) is management
philosophy that attempt to group
products with similar design or
manufacturing characteristics or
both
Group technology is the technique of
identifying and bringing together
related or similar parts in the
production process in order to
utilize the inherent economy of flow
production method
Similar parts are arranged into part
families, here part family possesses
similar design and or manufacturing
characteristics

Parts in the medium production quantity range are usually made in batches.
Disadvantages of batch production:
Downtime for changeovers and High inventory carrying costs

GT minimizes these disadvantages by recognizing that although the parts are different, there are groups

of parts that possess similarities.
The manufacturing efficiencies are generally achieved by arranging the production equipment into
machine groups or cells, to facilitate work flow
Grouping the production equipment into machine cells, where each cell specializes in the production f
part family is called cellular manufacturing

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cellular manufacturing is an
application of GT that involves
grouping machines based on
the parts manufactured by
them

HOW TO CREATE CELLULAR
1. Identify families of parts with similar flow paths
2. Group machines into cells based on part families
3. Arrange cells so material movement is minimized

4. Locate large shared machines at point of use

GT exploits the part similarities by utilizing The main objective of CM is to identify machine
similar processes and tooling to produce them. cells and part families simultaneously and allocate
part families to machine cell in way that minimizes
Machines are grouped into cells, each cell the intercellular movement parts .
specializing in the production of a part
family called

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WHEN TO USE GT AND CELULAR 1. Identifying the part families
MANUFACTURING Reviewing all of the parts made in the
plant and grouping them into part families
1. The plant currently uses traditional batch is a substantial task
production and a process type layout 2, . Rearranging production machines into
GT cells
this results in much material handling effort, high It is time-consuming and costly to
in process inventory, and long manufacturing lead physically rearrange the machines into
times cells, and the machines are not producing
during the changeover
2. The parts can be grouped into part families.
This necessary condition to apply group technology PROBLEM IN IMPLEMENTING OF
Each machine cell is designed to produce a given GROUP TECHNOLOGY
part family, or a limited collection of part families,
so it must be possible to group parts made in the
plant into families.

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“A collection of parts that possess similarities in geometric shape and size, or in the processing steps used in
their manufacture”

Part families are a central feature of group technology. There are always differences among parts in a family.

But the similarities are close enough that the parts can be grouped into the same family.

Two parts that are identical in shape and size but quite Ten parts are different in size, shape, and material, but quite
different in manufacturing: similar in terms of manufacturing
(a) 1,000,000 units/yr, tolerance = ±0.010 inch, 1015 All parts are machined from cylindrical stock by turning; some
parts require drilling and/or milling
CRsteel, nickel plate;
(b) 100/yr, tolerance = ±0.001 inch, 18-8 stainless steel

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Each cell specializes in producing one or a
limited number of part families

WAYS TO IDENTIFY PART FAMILIES

PARTS CLASSIFICATION
AND CODING

“Identification of similarities among parts and relating the
similarities by means of a numerical coding system”

Most time consuming of the three methods
Must be customized for a given company or industry
Reasons for using a coding scheme:
1. Design retrieval: access to a part that already exist
2. Automated process planning: process plans for similar code parts
3. Machine cell design: composite part concept
Most classification and coding systems are based on one
of the following:
❑P a r t d e s i g n a t t r i b u t e s
❑ Part manufacturing attributes
❑ Both design and manufacturing attributes

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Major dimensions Major process
Basic external shape Operation sequence
Basic internal shape
Length/diameter ratio Batch size
Annual production
Material type
Part function Machine tools
Cutting tools
Tolerances Material type
Surface finish

Hierarchical structure Chain-type structure Mixed-code structure
(monocode) (polycode)

❑ Interpretation of each ❑ Interpretation of each symbol ❑ Combination of hierarchical and
successive digit depends is always the same chain-type structures
on the value of the
preceding digit ❑ No dependence on previous

digits

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One of the first published classification and coding schemes for
mechanical parts
Basic code = nine (9) digits
Digits 1 through 5 = form code –primary shape and design
attributes (hierarchical structure)
Digits 6 through 9 = supplementary code –attributes that
are useful in manufacturing (e.g., dimensions, starting material)
Digits 10 through 13 = secondary code –production operation
type and sequence

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PART ROUTING MATRIX

Assembly

4679

5 8
2 10 12
13
11

A B C Raw materials

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Assembly

8 10 9 12

4 Cell 1 Cell 2 6 11
Cell 3

7

21 3 5

ABC
Raw materials

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LINE FLOWS IN A JOB SHOP
WITH THREE GT CELLS

JUMBLED FLOWS IN A JOB SHOP
WITHOUT GT CELLS

PRODUCTION FLOW ANALYSIS

“Method for identifying part families and associated machine groupings based on
production route sheets rather than part design data”
Work parts with identical or similar route sheets are classified into part families.
Advantages of using route sheet data
Parts with different geometries may nevertheless require the same or similar
processing
Parts with nearly the same geometries may nevertheless require different
processing

1. Data collection

operation sequence and machine routing for each part(number)

2.Sortationof process routings

parts with same sequences and routings are arranged into “packs”

3. PFA Chart

each pack is displayed on a PFA chart
- Also called a part-machine incidence matrix

4.Cluster analysis

purpose is to collect packs with similar routings into groups
- Each machine group = a machine cell

PRODUCTION FLOW ANALYSIS PRODUCTION FLOW ANALYSIS
BEFORE AFTER

1. Grouping parts into
families that follow
common sequences of
steps
2. Identifying dominants flow
pattern of part families as
a basic for location or
relocation of process.
3. Physically grouping
machines and process into
cells.



Product design Error to identify parts
• The problem in identifying part
families among many components
• GT promote design standardisation Costs part produced by plant
Material handling • The expense of parts classification and coding
• GT machine helps in efficient flow of
Cost management
material handling through the shop • Re-arranging the machine in the plant into the
Production inventory control
• Reduce overproduction and number of appropriate cells

Implementation Issues

inventory and make it efficient Reorganization – machine layout need reorganization every

Employee satisfaction so often
• Worker can visualize the production of the Work cell supervision – supervisors must be expert in
several field (milling, turning, grinding etc)
product. It can enhance their skill and
increase level of the job satisfaction Shop floor control /production planning – cell concept
leads to unbalanced workload on machines

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A Manufacturing Cell Direction of part movement within cell

with Worker Paths HM
VM
Source: J.T. Black, “Cellular
Manufacturing Systems Reduce Worker 3
Setup Time, Make Small Lot
Production Economical.” Industrial
Engineering (November 1983).

VM

L

Paths of three Worker 2 G
workers Worker 1
moving within Final
cell inspection

Material L Finished
movement part
S
Key: Out
In
S = Saw
L = Lathe
HM = Horizontal milling

machine
VM = Vertical milling machine
G = Grinder

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Each manufacturing cell is Manufacturing cell is defined
specifically used to process parts as the existence of more than
one workstations or machine
families. Part is classified into
families using Group Technology which could physically be
grouped together to process
either one or limited number of

similar products

Its implementation is not only The goal of manufacturing cell
process to increase the implement is to combine the
flexibility of process layout and
production speed but also its the efficiency of product layout
flexibility so that it can easily be

adjusted with market design

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“A composite part for a given family is a hypothetical part that includes all of the design
and manufacturing attributes of the family”

.

In general, an individual part in the family will have some of the features of the family, but not all of
them.
A production cell for the part family would consist of those machines required to make the composite
part.
Such a cell would be able to produce any family member, by omitting operations corresponding to
features not possessed by that part

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Typical objectives of cellular 1 To shorten manufacturing lead times
manufacturing: 2 To reduce WIP
3 To improve quality
4 simplify production scheduling

To reduce setup times

(a) The composite part for a family
of machine rotational parts

(b) The individual features of the
composite part

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