UNIT-II

Process Selection and Facility

Layout

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 Introduction
• Process selection: refers to deciding on the way production of
goods or services will be organized.
• Major implications
Capacity planning
Layout of facilities
Equipment
Design of work systems

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 Process selection and capacity planning influence
system design

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 Process strategy

• Key aspects of process strategy

– Capital intensive – equipment/labor
– Process flexibility
– Adjust to changes
– Design
– Volume
– Technology

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 Process Selection
• Variety ?
How much
• Flexibility ?
What degree
• Volume ?
Expected output
Answer to these questions will serve as a guide to select an
appropriate process.

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 Process Types
• Variety ?
How much
• Flexibility ?
What degree
• Volume ?
Expected output
Answer to these questions will serve as a guide to select an
appropriate process.

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 Process Types
• Job shop
Small scale, low volume, high job variety, high process
flexibility, high unit cost
• tool & dye shop, Veterinarian’s clinic.
• Batch
moderate volume, moderate variety, moderate
flexibility, moderate unit cost
• cookies, cake, movie theatre, paint ice cream, soft drink,
beer, magazines, books.

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 Process Types
• Repetitive/assembly line-
High volumes, low variety, low flexibility, low cost
• TV, Pencil, PC, Automobile
• Continuous-
Very high volumes of non-discrete goods, very low
variety, very low flexibility, very low cost
• steel, sugar, salt, electricity supply

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 Process Types

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 Check?
Fill the table with-very low, low, moderate high,
very high
 Process Types

Project:
• A non repetitive set of activities directed toward a unique goal
within a limited time frame.
e.g. Launching a new product or service, publishing a
book, building a dam, building a bridge.

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 Product and service profiling

Product or service profiling:

Can be used to avoid any inconsistencies by identifying key
product or service dimensions and then selecting appropriate
processes.
It is linking key product or service requirements to process
capabilities.

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 Automation

• Automation is the technology by which a process or procedure

is performed with minimal human assistance.

• Automation or automatic control is the use of various control

systems for operating equipment such as machinery, processes
in factories, boilers and heat treating ovens, switching on
telephone networks, steering and stabilization of ships, aircraft
and other applications and vehicles with minimal or reduced
human intervention.

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 Type of Automation

• Fixed
• Programmable
• Flexible

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 Type of Automation

Fixed automation
• Fixed automation refers to the use of special purpose
equipment to automate a fixed sequence of processing or
assembly operations.
• Each of the operation in the sequence is usually simple,
involving perhaps a plain linear or rotational motion or an
uncomplicated combination of two.
• It is relatively difficult to accommodate changes in the product
design. This is called hard automation.

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 Type of Automation

Fixed automation

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 Type of Automation

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 Type of Automation

Advantages:

1. Low unit cost

2. Automated material handling

3. High production rate.

Disadvantages:

1. High initial Investment

2. Relatively inflexible in accommodating product changes.

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 Type of Automation

Programmable Automation
• In programmable automation, the production equipment is
designed with the capability to change the sequence of
operations to accomodate different product configurations.
• The operation sequence is controlled by a program, which is a
set of instructions coded. So that they can be read and
interpreted by the system.
• New programs can be prepared and entered into the equipment
to produce new products.

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 Type of Automation

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 Type of Automation

Advantages:

1. Flexible to deal with design variations.

2. Suitable for batch production.

Disadvantages:

1. High investment in general purpose equipment

2. Lower production rate than fixed automation.

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 Type of Automation

Flexible automation:
• Flexible automation is an extension of programmable
automation.
• It is capable of producing a variety of parts with virtually no
time lost for changeovers from one part style to the next.
• There is no lost production time while reprogramming the
system and altering the physical set up.

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 Type of Automation

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 Type of Automation

Advantages:

1. Continuous production of variable mixtures of product.

2. Flexible to deal with product design variation.

Disadvantages:

1. Medium production rate

2. High investment.

3. High ‘unit cost relative to fixed automation.

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 Type of Automation

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 Plant Layout

• The configuration of departments, work centers, and

equipment, with particular emphasis on movement of work
(customers or materials) through the system.

• The basic objectives of layout design is to facilitates a smooth

flow of work, material & information through the system

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 Importance of Layout decisions

• The configuration of departments, work centers, and

equipment, with particular emphasis on movement of work
(customers or materials) through the system.

• The basic objectives of layout design is to facilitates a smooth

flow of work, material & information through the system

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 Importance of Layout decisions

• Requires substantial investments of money and effort

• Involves long-term commitments
• Has significant impact on cost and efficiency of short-term
operations.

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 Need for layout design
Inefficient operations
For Example: Changes in the design
High Cost of products or services
Bottlenecks

Accidents
The introduction of new
products or services

Safety hazards

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 Need for layout design

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 Basic layout type

Product layouts
Process layouts
Fixed-Position layout

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 Product layout

• Layout that uses standardized processing operations to achieve

smooth, rapid, high-volume flow
• car wash/ assembly line

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 Product layout

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 Product layout

Advantages
• High rate of output
• Low unit cost
• Labor specialization
• Low material handling cost
• High utilization of labor and equipment
• Established routing and scheduling

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 Product layout

Disadvantages
• Creates dull, repetitive jobs
• Poorly skilled workers may not maintain equipment or quality
of output
• Fairly inflexible to changes in volume
• Highly susceptible to shutdowns
• Needs preventive maintenance
• Individual incentive plans are impractical

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 Process layout

• Layout that can handle varied processing requirements

• hospital, university, bank, auto repair shop, public library,
machine shop

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 Process layout

Advantages
• Can handle a variety of processing requirements
• Not particularly vulnerable to equipment failures
• Equipment used is less costly
• Possible to use individual incentive plans

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 Process layout

Disadvantages
• In-process inventory costs can be high
• Challenging routing and scheduling
• Equipment utilization rates are low
• Material handling slow and inefficient
• Complexities often reduce span of supervision
• Special attention for each product or customer
• Accounting and purchasing are more involved

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 Fixed position layout

• In fixed-position layouts, the item being worked on remains

stationary, and workers, materials, and equipment are moved
about as needed.
• Weight, size, bulk, or some other factor makes it undesirable
or extremely difficult to move the product.
• Fixed-position layouts are used in large construction projects
(buildings, power plants, dams), shipbuilding, and production
of large aircraft and space mission rockets

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 Fixed position layout

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 Fixed position layout

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 Cellular layout

• Layout in which machines are grouped into a cell that can

process items that have similar processing requirements.

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 Cellular layout

• .

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Cellular layout v/s Process layout

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 Other service layout

• Warehouse and storage layouts

• Retail layouts
• Office layouts

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 Line Balancing

• Line Balancing is the process of assigning tasks to

workstations in such a way that the workstations have
approximately equal time requirements.
• It minimize the idle time along the line and results in higher
utilization of labor and equipment.

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 Line Balancing

• The major difficulty associated with line balancing is the

difficulty of forming task bundles that have same duration.
1. Different equipment requirements or activities are not
compatible
2. Required technological sequence may prohibit otherwise
desired task combination.

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 Line Balancing

Cycle time
• Cycle time is the maximum time allowed at each workstation
to perform the assigned tasks before the work moves on.
• It establish the output rate of line.
Let us cycle time is 5 minutes then output rate is 1unit /5 minutes

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 Line Balancing

Cycle time

In the above case there are two possibilities of cycle time

I. cycle time 1minute
II. cycle time 2.5 minutes when all the workstations are
assembled as single station.
It establish the potential range of the output of the line.

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 Line Balancing

𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑡𝑖𝑚𝑒 𝑝𝑒𝑟 𝑑𝑎𝑦

Output rate=
𝑐𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒
What will be the out range for the company per day that is
operating 8 hrs /day. The cycle time is 1minutes and 2.5 minutes.

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 Line Balancing

What will be the out range for the company per day that is
operating 8 hrs /day. The cycle time is 1minutes and 2.5 minutes.
ANS 192-480.

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 Line Balancing

No of workstations needed=f(output rate, ability to combine

elemental tasks into workstations)
σ𝑡
𝑁𝑚𝑖𝑛 =
𝑐𝑦𝑐𝑙𝑒 𝑡𝑖𝑚𝑒
𝑁𝑚𝑖𝑛 = theoretical minimum no of stations.
σ 𝑡= sum of task time

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• For the question below if the output rate is 480/day and line
operates for 8hrs. What will the cycle time ? What will be the
minimum no of workstations needed?
• Ans 1,3
• For the question below if the output rate is 480/day and line operates for
8hrs. What will the cycle time ? What will be the minimum no of
workstations needed? Assign the task in order of most number of followers.
Also determine percentage idle time and efficiency.
• For the question below if the output rate is 480/day and line operates for
8hrs. What will the cycle time ? What will be the minimum no of
workstations needed? Assign the task in order of most number of followers.
Also determine percentage idle time and efficiency.
Ans: Cycle time = 1 minute
Minimum no of workstation= 3
% idle time= 16.67%
Efficiency= 83.33%