©T.C.

Chang

PRODUCTION FACILITY

A building or area where goods are made

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• Production Facilities allows the smooth

transformation of the inputs into outputs i.e
manufacturing process with the required
machinery tools manpower etc..
• While Production Systems ensures that there
is the proper methods, arrangements,
procedure is adopted to produce different
types of goods or services.

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• Before starting of any production

process the organisation has to decide
about the facilities to produce the
same.
• Facilities has to be installed on the
basis of the requirement and the
availability of the resources to the
organisation.

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Production Facilities required by the organization is

decided by the following;
1.Types of product
2. Production quantity
3. Market
4.Product Demand
5.Competitiors for the product
6.Location
7.Product Variety
8.Machines and equipments

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9.Tools
10.Technology
11. Inspection Aid
12.Process Details
13.Operating Personnel
14.Production Volume

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• Production quantity – refers to the

number of units produced annually
of a particular product type.
»Low production – quantites in the range
1 to 100 units per year
»Medium production – from 100 to 10,000
units annually
»High production – 10,000 to millions of
units.

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• Product variety – refers to different product designs

or types that are produced in the plant
• Layout means arrangement of facilities in a particular
unit to ensure the smooth and proper flow of
production
Layout Planning involves decisions about the
physical arrangement of economic activity centers
within a facility.

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Four Questions in Layout Planning

• What centers should the lay out include?
• How much space and capacity does each center
need?
• How should each center’s space be configured?
• Where should each center be located?

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Goal of Layout Planning

• Is to allow workers and equipment to operate at peak

effectiveness and efficiency.
• Types of Layout
• 1.Process/Functional Layout
• 2.Product Layout
• 3.Hybrid Layout
• 4.Fixed-position Layout

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BATCH REDUCTION OR ELIMINATION

Process/ Functional Layout

Material

Punch Grinders
Presses Shipping
Receiving Warehouse
Warehouse
Finished Goods

Lathes
Drill Presses Inspection

Ship

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Process lay out

• Groups work stations or departments
according to functions
ex. All drilling equipment is located in one
area of a machine shop , or all budget apparel
is displayed in one area of a department store.
• The process lay out is most common
when the same operation must
intermittently produce many different
products or serve many different
customers.
• Demand levels are too low or
unpredictable

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Advantages of process lay out

• It is more flexible
• Equipment utilization is high
• Employee supervision can be
specialized

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Disadvantages of process lay out

• Processing rates tend to be slower

• Productive time is lost in changing from one
product or service to another.
• More space and capital are tied up in
inventory
• The time lags between job starts and end
points are relatively long
• Materials handling tends to be costly

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Product lay out

• Arranges work stations or departments
in a linear path.
• It is often called production or assembly
line
• Disadvantages;
–Product lay outs often rely heavily
on specialized, capital-intensive
resources.
–These lay outs are therefore riskier
for products or services with short
or uncertain lives.

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BATCH REDUCTION OR ELIMINATION

Product Layout
Finished
Grinders Inspection Goods & Customer
4 5 Shipping
6

Materials
Punch Drill Press
Presses Lathes Warehouse
2 1
3

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Advantages

• Faster processing rates

• Lower inventories
• Less unproductive time lost to
changeover

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Hybrid lay out

• Combines elements of both a product and
process focus.
• Arranges some portions of the facility as a
process lay out and others as a product lay out.
• Other hybrid lay outs ;
• FMS – flexible manufacturing systems
• GT – Group technology
• OWMM – one worker ; multiple machines
• Each of these technologies help achieve
repeatability even when product volumes are
too low to justify dedicating a single line to one
product.

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GROUP LAYOUT
(cellular layout)

• combination of 1 & 2
• trade-off interdepartment mtl
handling w/ intra-department
M.H.

Each cell produces one or a few

families of parts.

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Group technology

• This manufacturing technique groups parts or

products with similar characteristics into
families and sets aside groups of machines for
their production.
• Families may be based on size, shape ,
manufacturing or routing requirements or
demand.
• The goal is to find a set of products with similar
processing requirements and minimize machine
changeover or set up. (ex. Bolts might be
assigned to the same family because they all
require the same basic processing steps
regardless of the size and shape.

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Information for grouping parts into

families
• Visual inspection of the different parts
made
• Examining the final product designs
and process design specifications
• Organize the machine tools needed to
perform the basic processes into
separate areas called cell.

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Fig.10.3

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Benefits of gt

• Less set up time

• Lower work-in-process inventory
• Less materials handling
• Reduced cycle time
• Increased opportunities for
automation

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One worker, multiple machine (OWMM)

• A process in which a worker operates

several different machines
simultaneously to achieve a line flow.
• There are several different machines in
the line

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One worker, multiple machine

• Reduces inventory as well as labor

requirements
• Inventory is cut because materials do not
pile up in queues but move directly into
the next operation.
• The addition of several low-cost
automated devices can maximize the
number of machines included in OWMM:
automatic tool changers, loaders and un
loaders, start and stop devices, and fail-
safe devices that detect defective parts or
products.

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Flexible manufacturing systems

• Is a configuration of computer-
controlled , semi-independent work
stations where materials are
automatically handled and machine
loaded. Like NC (numerically
controlled) machines and industrial
robots.
• FMS is a type of flexible automation and
is part of CIM.

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Key components of fms;

• Several computer-controlled work

stations, such as CNC
(computerized numerically
controlled ) machines or robots,
that perform a series of operations
• A computer-controlled transport
system for moving materials and
parts from one machine to another
and in and out of the system
• Loading and unloading stations

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Flexible manufacturing system

• Workers bring raw materials for a part family

to the loading points, where the FMS takes
over. Under the direction of the central
computer , transporters begin delivering the
materials to various work stations, where
they pass through a specific sequence of
operations unique to each part. The route is
determined by the central computer.
• The goal is to synchronize activities to
maximize the system’s utilization.

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Fixed –position lay out

• The product is fixed in place; workers, along

with their tools and equipment, come to the
product to work on it.
• This type of lay out makes sense when the
product is particularly massive or difficult to
move
• It minimizes the number of times that the
product must be moved and often is the only
feasible solution.

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