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Lecture7 PDF
Lecture7 PDF
The batch may be produced once or at irregular intervals. This type of production is
very common and involves the use of flexible systems.
Continuous production systems
Involves the manufacture of identical products on which the plant is fully engaged.
Two types
Mass production systems where the equipment are not specially designed for one
component alone. After the manufacture of one component for a large quantity,
operations can be switched to another but will require major tooling changes. Eg
Toyota car types)
Flow production systems where the equipment and layout have been primarily
designed to manufacture one component and changes in components are not possible
without substancial changes in plant layout and tooling. E.g sugar, chemicals, petrol,
electricity)
Jobbing
Batch
Line/Mass
Flow
Plant Layout
A good layout requires determining
Capacity and space requirements
Material handling equipment
Environment and aesthetics
Flow of information
Cost of moving between the various work areas
Strategies
Fixed position layout (ship building, construction sector)
Product oriented layout (high volume, low variety, best m/c util.)
Mostly for jobbing type of production. Project remains stationary and requires
workers and equipment to come to the one work area.
Layout decided upon on an ad hoc basis
Limitations
1. There is limited space at virtually all sites
2. At different stages of the project, different material is required
3. The volume of material required is dynamic
Alternative
Use of Group Technology for off site manufacturing of components
Process Oriented Layout
Mostly used for batch type of production (low volume, high variety)
Transformation resources or similar functions are grouped together in the same work
centre usually a department, under the management and control of a functional
specialist. E.g engineering production, garage services, film processing etc
Grinding
Store
Drilling
Painting/Electroplating
lathes
Assembly
Inspection
Shipping
The most common tactic is to arrange departments or work centres in the most
economical locations, minimising material handling costs
Place departments with large interdepartmental flow of parts or people next to one
another.
Prepared by: Dr D.K.Hurreeram
August 04
i,j
= individual departments
Xij
Cij
Example
Procedure
1. Determine the number of trips between each department and construct a from to
matrix
2. Determine space requirements and distance between each department
3. Develop an initial schematic diagram
4. Determine the cost of this layout (multiply trips by distance)
5. By trial and error try to improve the layout
6. Prepare a detailed plan that evaluates other factors
Advantages of Process oriented Layout
1. It enables changes in quantity and type of products manufactured to be introduced
easily
2. Flexibility in terms of production types and ranges
3. Less duplication of specialised equipment (lower investment)
4. Workers and supervisors can become highly skilled in the operation of a single
type or group of production resources
Prepared by: Dr D.K.Hurreeram
August 04
i=1
Arrange production equipment into machine groups or cells to facilitate work flow
Part family collection of parts which are similar either because of geometric
shape and size or because similar processing steps are required in their
manufacture
Organised around a product or a family of similar high volume, low variety products:
Product is standardised
Supplies of raw material and components are adequate and of uniform quality
Line balancing (high personnel and facility utilisation and equity between
employees work loads
To :
Tno:
nm:
Q:
Tsu:
Set up time
Compute:
1. Manufacturing Lead time MLT
2. Production Rate
3. Components of Operation time
4. Capacity
5. Utilisation and Availability
6. Work in progress
See Example