Production

System Design
 Production System
Design entails:
• Process planning
• Technology choice
• Capacity planning
• Layout decision
• Location choice
• Work design
 Production System
Design entails:
• Process planning
• Technology choice
• Capacity planning
• Layout decision
• Location choice
• Work design
Facility
Layout
Design
 Basic Types of Layouts
 Process Layout
 Machines grouped by process they perform
 Product Layout
 Linear arrangement of workstations to
produce a specific product
 Fixed Position Layout
 Used in projects where the product cannot
be moved
 Basic Types of Layouts
 Process Layout
 Machines grouped by process they perform
 Product Layout
 Linear arrangement of workstations to
produce a specific product
 Fixed Position Layout
 Used in projects where the product cannot
be moved
 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
Product layout

Work Work Work

station 1 station 2 station 3

A, B C D
0.3 0.4 0.3
minute minute minute
• Layout decisions impact the initial
investment and operating costs of
any facility.
- impacts capacity decisions : no
of workers and/or machines needed
- impacts internal transportation
costs
 Product Layout

• Line Balancing

– Assignment of tasks which need to be

done to produce/assemble one unit of a
product to individual workstations
without exceeding the set cycle time
limit to minimize the number of
workstations
 Product Layout

• Line Balancing

– Assignment of tasks which need to be

done to produce/assemble one unit of a
product to individual workstations
without exceeding the set cycle time
limit to minimize the number of
workstations
• Workstation: A physical stage in
production/assembly where a number of
tasks are done by one worker

• Cycle Time : Maximum workload (in time

units) allowed at a workstation
• Maximum throughput:1/CT
• Theoretically minimum # of workstations
 Line Balancing
WORK ELEMENT PRECEDENCE TIME (MIN)
A Press out sheet of fruit — 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and package B, C 0.3
• Operating time: 40 hrs per week
• Demand per week: 6000 units
 Line Balancing
WORK ELEMENT PRECEDENCE TIME (MIN)
A Press out sheet of fruit — 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and package B, C 0.3

0.2
40 hours x 60 minutes B / hour 2400
CT = = = 0.4 minute
6,000 units 6000
0.1 A D 0.3
0.1 + 0.2 + 0.3 + 0.4 1.0
N= = = 2.5 workstations
0.4 0.4
C
0.4
 Line Balancing
WORK ELEMENT PRECEDENCE TIME (MIN)
A Press out sheet of fruit — 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and package B, C 0.3

0.2
40 hours x 60 minutes B / hour 2400
CT = = = 0.4 minute
6,000 units 6000
0.1 A D 0.3
0.1 + 0.2 + 0.3 + 0.4 1.0
N= = = 2.5 workstations
0.4 0.4
C 3 workstations
0.4
 Line Balancing
WORK ELEMENT PRECEDENCE TIME (MIN)
A Press out sheet of fruit — 0.1
B Cut into strips A 0.2
C Outline fun shapes A 0.4
D Roll up and package B, C 0.3

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, C

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, C
B 0.1 C, D

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, C
B 0.1 C, D
2 C 0.0 D

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, C
B 0.1 C, D
2 C 0.0 D
3 D 0.1 none

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION Work
ELEMENT Work
TIME Work
ELEMENTS
station 1 station 2 station 3
1 A 0.3 B, C
B A, B C
0.1 D C, D
2 C 0.0 D
0.3 0.4 0.3
3 D minute 0.1
minute
none
minute

CT = 0.4
0.2
B N=3

0.1 A D 0.3

C
0.4
 Line Balancing
REMAINING REMAINING
WORKSTATION Work
ELEMENT Work
TIME Work
ELEMENTS
station 1 station 2 station 3
1 A 0.3 B, C
B A, B C
0.1 D C, D
2 C 0.0 D
0.3 0.4 0.3
3 D minute 0.1
minute
none
minute

CT = 0.4
0.2
B N=3

0.1 + 0.2 + 0.3 + 0.4 1.0

E= 0.1 A = D0.833
= 0.3 = 83.3%
3(0.4) 1.2

C
0.4
AIC Netbooks
Process Layouts
Manufacturing 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
Manufacturing 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
Manufacturing 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
Designing Process Layouts
 Minimize material handling
costs
 Block Diagramming
 Minimize nonadjacent loads
 Use when quantitative data
is available
 Relationship Diagramming
 Based on location preference between areas
 Use when quantitative data is not available
 Muther relationships
• Degrees of closeness

– A : Absolutely necessary
– E : Very important
– I : Important
– O : Ordinary importance
– U : Unimportant
– X : Undesirable
 Factors
• Use same equipment/facilities
• Share same personnel/records
• Sequence of work flow
• Ease of communication
• Unsafe or unpleasant conditions
• Similar work performed
Designing Process Layouts
 Minimize material handling
costs
 Block Diagramming
 Minimize nonadjacent loads
 Use when quantitative data
is available
 Relationship Diagramming
 Based on location preference between areas
 Use when quantitative data is not available
 Hybrid Layouts
 Cellular layouts
 Group machines into machining cells
 Flexible manufacturing systems
 Automated machining & material
handling systems
 Mixed-model assembly lines
 Produce variety of models on one line