Process Selection and Facility Layout

Chapter 6
 Process Selection
– Refers to the decision on the
way production of goods or
services will be organized Facilities and
Forecasting Capacity Equipment
– It has major implications for Planning
• Capacity planning
• Layout of facilities Product and Layout
• Equipment Service Design
• Design of work systems
Process
Technological Selection Work
Change Design
Types of Processing
 Types of Processing

1. Job Shop: 2. Batch:

https://www.youtube.com/watch?v=uIVK9w324WA
 Types of Processing

3. Repetitive/Assembly: 4. Continuous:

https://www.youtube.com/watch?v=8_lfxPI5ObM https://www.youtube.com/watch?v=6PDw8d18tBI
 Automation

➢ Machinery that has sensing and control 1. Fixed automation

devices that enable it to operate
automatically

• Fixed automation
• Programmable automation
• Flexible automation
 Automation

2. Programmable automation
✓ Numerically Controlled (N/C) Machines
• Involves the use of high-cost, general-purpose
equipment controlled by a computer program that
provides both the sequence of operations and specific
details about each operation

✓ Computer-Aided Manufacturing (CAM)

 Automation

✓ Robot 3. Flexible automation

– evolved from programmable automation. It
uses equipment that is more customized
than that of programmable automation. A
key difference between the two is that
flexible automation requires significantly
less changeover time.
 Facilities Layout

• Layout
– the configuration of departments, work
centers, and equipment, with particular
emphasis on movement of work (customers or
materials) through the system
– Facilities layout decisions arise when:
• Designing new facilities
• Re-designing existing facilities

4 Basic Types:
• Product layouts – used for repetitive or continuous
• Process layouts – used for intermittent, job shop or
batch
• Fixed-Position layout – is used to make large items
like building, ship, plane
• Combination layouts – used for hospitals,
supermarkets
 Facilities Layout

• Product Layout ✓ Cycle time

The goal of a product layout is to arrange – The maximum time allowed at each
workers or machines in the sequence that workstation to complete its set of tasks on a
operations need to be performed unit
✓ Line balancing – Cycle time also establishes the output rate
The process of assigning tasks to of a line
workstations in such a way that the
Operating time per day
workstations have approximately equal
time requirements
Cy cle time =
Desired output rate
✓ Goal:
Obtain task grouping that represent
Operating time per day
approximately equal time requirements
since this minimizes idle time along the Output rate =
line and results in a high utilization of Cy cle time
equipment and labor
 Work Stations

• The required number of workstations is a • Precedence diagram

function of – A diagram that shows elemental tasks and
– Desired output rate their precedence requirements
– Our ability to combine tasks into a
workstation
• Theoretical minimum number of stations

N min =
t
Cy cle time
where
N min = theoretical minimumnumberof stations
 t = Sum of task times
 Illustrative Example
• Questions:
1. Draw a Precedence Diagram
Task Immediate Predecessor Task Time (in minutes)
A ------ 0.2
2. Assuming an eight-hour workday, compute the cycle
B A 0.2
time needed to obtain an output of 400 units per
C ------ 0.8 day.
D C 0.6 3. Determine of minimum number of workstations
E B 0.3 required.
F D, E 1.0
4. Assign tasks to workstations using this rule: Assign
G F 0.4
tasks according to greatest number of following
H G 0.3
tasks. In case of a tie, use the tiebreaker of
assigning the task with the longest processing time
first.
5. Compute the resulting percent idle time and
efficiency of the system.