FLOW ANALYSIS

Arief Rahman, 2021

Lecture Note Series

Laboratorium Ergonomi dan Perancangan Sistem Kerja
 MATERIAL MANAGEMENT SYSTEM

Production Forecasts

Material Management System

Production Control

Stock Requisitions

Purchasing Department E.D.I

• The subjects of material management systems are the Bill of Lading

materials, parts, and supplies purchased by a firm and
required for the production of its product. Order Payment
Vendors

• The resources of material management systems include: Bill of Lading

Inventory records
1. The production control and purchasing functions Transportation
2. The vendors
Move ticket
3. The transportation and material handling equipment Kanbans
required to move the materials, parts, and supplies Receiving
Reports

4. The receiving, storage, and accounting functions Receiving Dept. Accounting Dept.

Move ticket
Kanbans

Note :
Material Handling
Flow subject
Communication

Stores Departement
 Material Flow System
• The subjects of material flow systems are the
materials, parts, and supplies used by a firm in
manufacturing products and components within its
facility.
• The resources of material flow systems include:
1. The production control and quality control
departments
2. The manufacturing, assembly, and storage
departments
3. The material handling equipment required to move
materials, parts, and supplies
4. The factory warehouse
Physical Distribution System
• The subjects of physical distribution systems
are the finished goods produced by a firm.

• The resources of physical distribution systems

include:
1. The customer
2. The sales and accounting departments,
and warehouses
3. The material handling and transportation
equipment required to move the finished
product
4. The distributors of the finished product
 MATERIAL FLOW SYSTEM

• Good knowledge of material The work simplification approach to material flow

flow systems is of value to the includes
a. Eliminating flow by planning for the delivery of
facilities planner be- cause
materials, information, or people directly to the
these systems define the point of ultimate use and eliminating
overall flow environment intermediate steps
within which material b. Minimizing multiple flows by planning for the
movement takes place. flow between two consecutive points of use to
• The principle of minimizing take place in as few movements as possible,
total flow represents the work preferably one
c. Combining flows and operations wherever
simplification approach to
possible by planning for the movement of
material flow. materials, information, or people to be combined
with a processing step
AVOID THE INTERRUPTED FLOW

A B C D

E F G H
UNINTERRUPTED FLOW PATHS

A F C H

E B D G
INTERRUPTED FLOW PATHS
Minimizing the Cost of Flow

a. Eliminate unnecessary movements of material by

reducing the number of manufacturing steps.
b. Minimize manual handling by minimizing travel
distances.
c. Eliminate manual handling by mechanizing or
automating flow.
d. Minimize material handling by reducing the flow
density through containerization.
 Flow within
Workstations Motion

• Motion studies and ergonomics

considerations are important in
establishing the flow within workstations.
• Simultaneous flow implies the
coordinated use of hands, arms, and
feet. Hands, arms, and feet should begin
and end their motions together and
should not be idle at the same instant
except during rest periods.
• Symmetrical flow results from the
coordination of movements about the
center of the body.
• The left and right hands and arms should
be working in coordination. Natural flow
patterns are the basis for rhythmical and
habitual flow patterns. Natural
 Flow within a Product Department

End-to-end
Back-to-back

Front- to-front
Circular

one operator works on two

Odd-angle workstations or more

one operator works at each workstation

Flow within a Process Department

Parallel Perpendicular Diagonal

• In a process department, similar or identical machines are grouped in the same department.
• A minimal amount of flow should occur between workstations within departments.
• Flow typically occurs between workstations and aisles.
• Flow patterns are dictated by the orientation of the workstations to the aisles.
Flow within Product and Process Departments with Material Handling Considerations (1)

a. Line Flow
Pattern

• Typical of the flow structures

found in the automotive
industry.
• The line flow structure is most
effective for transfer line– or
assembly line–type
production, where there is
minimal or no backtracking.
Flow within Product and Process Departments with Material Handling Considerations (2)

b. Spine Flow Pattern c. Loop Flow Pattern

• The spine flow is characterized by the presence of a

unidirectional or bidirectional material handling device
operating along a central spine.
• The workstations are situated along the main flow line with
connection through the use of spurs.
• The spine flow structure can be used for both within-
department flows and between-department flows.
• The loop flow is characterized by the presence of a loop
that services the workstations around it.
• The flow direction can be unidirectional or bidirectional.
• The workstations are positioned either in the inside of the
loop or along the outside area of the loop

d. Tree Flow Pattern

• The workstations can be positioned in a single tree or in multiple
trees that are linked together by a centralized material handling
device.
• This type of flow structure can be found in facilities that utilize
robotic-type material handling for moving parts from workstation to
workstation.
 Flow between Departments

ON THE SAME SIDE BUT AT OPPOSITE ENDS ON THE SAME SIDE BUT AT OPPOSITE ENDS
AT THE SAME LOCATION AT THE SAME LOCATION

ON ADJACENT SLIDES ON ADJACENT SLIDES ON OPPOSITE SIDES ON OPPOSITE SIDES

• Flow between departments is a criterion often used to evaluate overall flow within a facility.
• An important consideration in the flow between departments is the location of the pickup and delivery stations
for each department. The locations of the pickup and delivery stations are often fixed
• Production line departments
• Fixed materials location departments
• Product family departments
• Process departments

Types of Layout based on the flow of materials

and Pattern of Flow
 A. PRODUCT LAYOUT

Known by names such as:

• Flowline layout
• Production Line Layout
• Assembly Line Layout
• Layout by Product

• Machines and workstations are arranged along the product route in the sequence that corresponds to
the sequences of operations the product undergoes.
• Used by companies that manufacture a single or few items in large quantities, such as car’s
asssembly plant.
• Benefits : shorten material handling time, reduced processing time, and easier on planning and
control.
B. PROCESS LAYOUT

Known by names such as:

• layout by process
• job-shop layout

• Machines and workstations are arranged on the basis of processes they perform.
• Similar machines are placed together in one departement.
• Benefits : produce many variation of product in small quantity, offer flexibility, personnel
become expert in a particular process.
• Disadvantages : increased MH’s cost, traffic congestion, more complexity on planning and
control.
C. FIXED POSITION LAYOUT

• The product does not move from one location to another. Instead the equipment
and processes are brought to the product itself.
• Apply for bulky product and cannot be easily transported such as shipbuilding,
aircraft, dam, road, house, brigde, etc.
• Benefits : usually expensive, less chance for damage, reduces tranportation
 D. PRODUCT FAMILY LAYOUT

• Known by names such as group

technology-based layout or GT
layout.

• Each machine set and corresponding part set form a manufacturing “cell” and a part of
“family”.
• Benefits : increase quantity of production compared to Job-shop layout, easily to plan and
control. Reducing traffic congestion, MH costs, and WIP inventory.
Volume-variety
Layout Classification
Procedural Guide for Combining Workstations in
Planning Departments
ASSEMBLY FLOW PATTERN

Combination Assembly Line Patern Tree Assembly Line Patern

Sub-assembly Sub-assembly
Sub-assembly Sub-assembly
Sub-assembly

Sub-assembly Sub-assembly

main assembly line

Sub-assembly
Sub-assembly Sub-assembly

main assembly line

ASSEMBLY FLOW PATTERN

Dendretic Assembly Line Patern

Sub-assembly

assembly line #1 Overhead Assembly Line Patern

Final Assembly Product

assembly line #2 2nd Floor

Sub-assembly Sub-assembly
Sub-assembly

1st Floor
FLOW EVALUATION TECHNIQUES
Objective Function on Flow Evaluation

Minimize : ∑ i ∑ j cij . f ij .d ij

cij = Transportation cost for unit-load from i to j

fij = movement frequency from i to j

dij = distance from i to j

Several approaches to measure the distance
Facility j

(Xj, Yj)

Xi : Position of Facility i on x axis

Yi : Position of Facility i on y axis
Dij :Distance from i to j

(Yj-Yi)

Facility i

(Xi, Yi) K
(Xj-Xi)
 Several approaches to measure the distance

EUCLIDEAN AISLE DISTANCE

Distance i to j is measured by calculating the actual distance using pedometer.
If i to j passing through k then the distance = a + b + c
𝑑𝑑𝑖𝑖𝑖𝑖 = (𝑋𝑋𝑖𝑖 − 𝑋𝑋𝑗𝑗 )2 + (𝑌𝑌𝑖𝑖 − 𝑌𝑌𝑗𝑗 )2
Facility j

SQUARED EUCLIDEAN c
Facility
𝑑𝑑𝑖𝑖𝑖𝑖 = (𝑋𝑋𝑖𝑖 − 𝑋𝑋𝑗𝑗 )2 + (𝑌𝑌𝑖𝑖 − 𝑌𝑌𝑗𝑗 )2 i
Facility k

a
b
RECTILINEAR
𝑑𝑑𝑖𝑖𝑖𝑖 = 𝑋𝑋𝑖𝑖 − 𝑋𝑋𝑗𝑗 ) + 𝑌𝑌𝑖𝑖 − 𝑌𝑌𝑗𝑗 ADJACENCY
If facility i and j has a relation directly (adjacency), thenadjacency value = 1,
otherwise = 0
TCHEBYCHEV dik = dkj = 1
𝑑𝑑𝑖𝑖𝑖𝑖 = max( 𝑋𝑋𝑖𝑖 − 𝑋𝑋𝑗𝑗 ) , 𝑌𝑌𝑖𝑖 − 𝑌𝑌𝑗𝑗 ) Facility
Facility k dij = 0
i Facility j
 A. STRING DIAGRAM
String Diagram shows the flow of material by connecting each facilities using
string relation on the layout.

W/H
PENGOLAHAN FINISH
LIMBAH 6 Procedures :
GOOD •Stick a nail on the beginning
flow and end flow of a
12 facility
1 7 •Make a link between
13 10 11 machines based on the
3 designing flow by using string
from nail to nail.
4 •Apply different color of
W/H MATERIAL
2 8 9 string todistict the spesific
5
flow.

Kemungkinan terjadinya kemacetan aliran

B. FROM TO CHART

• Known also as Travel Chart

• A conventional technique to arrange or evaluate the material
handling in a production line
• Providing the volume of flow and present the flow balancing in a
production line
• FTC will show the total volume of handling, distance of
movement for every machine, and the backtracking flow.
EXAMPLE :
• Colect the volume of handling, space of each room, and production routing for
each product.

VOLUME OF % VOLUME OF
PRODUCT FLOW OF PROCESS
HANDLING HANDLING

P1 2000 Kg 20 A-B-C-D-E-F-G-H-I

P2 2000 Kg 20 A-C-D-F-G-I

P3 2500 Kg 25 A-D-B-E-H-F-I

P4 2000 Kg 20 A-C-D-B-E-G-I

P5 500 Kg 5 A-E-F-G-H-I

P6 500 Kg 5 A-D-C-B-F-G-H_I

P7 500 Kg 5 A-C-D-H-D-G-I
DIMENSION OF EACH DEPARTEMENT

DEPARTEMENT SPACE (meter )

A 10 x 10
B 5x5
C 8 x 10
D 10 x 5
E 25 x 10
F 5x5
G 5 x 10
H 8x8
I 16 x 16
• Initial From to Chart

FROM
TO A B C D E F G H I
A
B 20 5 25+20

C 20+20+5 20 5

D 25+5 20+20+20+5 5

E 5 25+20 20

F 5 20 20+5 25

G 5 20 20+20+5+5

H 5 25 20+5+5

I 25 20+20+5 20+5+5
Movement P1
of A to B with %handling = 20
 INITIAL FLOW
FROM
TO A B C D E F G H J
A 0
B 20 5 45 70
C 45 20 5 70
D 30 65 5 100
E 5 45 20 70
F 5 20 25 25 75
G 5 20 50 75
H 5 25 30 60
J 25 45 30 100

100 70 70 100 70 75 75 60 0 620

VOLUME MEASURES OF FLOW
FORWARD BACKWARD
Distance form Distance Distance form
diagonal Moment coefficient Moment diagonal
(20+20+65+20+25+50+30+30) (260 x 1) (10 x 1) (5+5)
= 260 = 260 1 =10 =10
(45+20+20+45) (130 x 2) (70 x 2) (45+25)
=130 = 260 2 =140 =70
(30+45+5+25+25) (130 x 3)
=130 = 390 3 0 0
(5+5+5) (15 x 4) (5 x 4)
=15 = 60 4 =20 5
0 0 5 0 0
0 0 6 0 0
970 1140 170
85% 15%
BACK TRACKING

•Based on the exaple, it showed that the backtracking

volume = 15% from total flow (see the red text)
•Smaller the backtracking, the better flow will be
performed.
•Case of backtracking :
P3  A-D-B-E-H-F-I
If the flow may be modified as below:
P3  A-B-D-E-F-H-I
Then the balance of flow will be better
FTC after P3’s modification become (A-B-D-E-F-H-I)

FROM
TO A B C D E F G H I
A
B 20+25 5 20

C 20+20+5 20 5

D 5 25 20+20+20+5 5

E 5 20 20+25

F 5 20 20+5+25

G 5 20 20+20+5+5

H 5 25 20+5+5

I 20+20+5 20+5+5+25
 After Modification

FROM
TO A B C D E F G H I
A
B 45 5 20

C 45 20 5

D 5 25 65 5

E 5 20 45

F 5 20 50

G 5 20 50

H 5 25 30

I 45 55
 VOLUME MEASURES OF FLOW
FORWARD BACKWARD
Distance
Distance form Distance form
diagonal Moment coefficient Moment diagonal
360 360 1 10 10
180 360 2 40 20
30 90 3 0 0
15 60 4 20 5
0 0 5 0 0
0 0 6 0 0
0 0 7 0 0
0 0 8 0 0
870 940 70
93% 7%
Initial Layout

A B C D

I H G F
 C. ACTIVITY RELATIONSHIP CHART

An relationship chart of displaying the closeness

rating among all pairs of activities or departments. In
an ARC there are six closeness ratings which may be
assigned to each pair of departments, as well as nine
reasons for those ratings (each is assigned by a reason
code)

Procedures:
1. Identify all facilities or departement
2. Plot all facilities or departement on ARC diagram
3. Determine the closeness rating for each facilities inter-relation
4. Determine the reason of closeness
CLOSENESS SYMBOLS

Line Numerical
Value Closeness
code weights

A Absolutely necessary 16

E Especially important 8

I Important 4

O Ordinary closeness OK 2

U Unimportant 0

X Undesirable 80
Example of Closeness value
Code Reason
1 Same Dock
2 Flow of Material
3 Service
4 Convenience
5 Inventory Control
6 Communcation
7 Same Personnel
8 Cleanlieness
9 Flow of Parts
1 Lathe (10 x 15) ACTIVITY
A
2 Drill 1(10 x 10)
3
O RELATIONSHIP
CHART
4
I A
3 Mill (20 x 20)
1 A 2
A
E 3 O 5 I
7
4 Punch Press (15 x 15)
1 A I 4 X
5
E A 6
U 4 A
5 Centerless Grinder (15 x 15)
2 E 7 E 7 O 5 U
U 7 O 8 O 7
U 1
U
6 Shaper (10 x 20)
2
U 4 O 1 O 2 U 8
E
2
O 3
E 6 U A 3
U 3
I
1
7 Planer (10 x 20) O 5
I 4
U 1 O 5 U 2
5
O 2
O U 4 U 4 U 2
2
E 7 A 9
E
6 O 8
8 Drill 2(10 x 10) 3 4
U I 7 O 4 I
6
9 Mill 2(15 x 20)
5
U 6
U X 3

I 3
E U 9
5
E 5 A 9
10 CNC Machine (10 x 25) 1 2
U I
11 Punch Press 2 (15 x 15)
3 X 5

O 9
1
12 Vertical Turret Lathe (10 x 10)
Reading Task

• Read the queuing model for:

a. single machine or single server with 1 line of queuing,and
b. 3 different machines (follow paralel arrangement) with 1 line of
queuing on each machine

M
a

M1 M2 M3
b
Thank You