Process Selection &

Facility Layout

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PROCESSSELECTION

◦ Processes convert inputs into outputs

◦ Process selection refers to deciding on the way productionof

goods or services will beorganized

◦ It affects the entire organization and its ability to achieve its

mission and effective supply chain system
PROCESSSELECTION(CONTD.)

◦ Key aspects help in process selection are –

◦ Capital Intensity – The mix of equipment and labor that will be
used by the organization

◦ Process Flexibility – The degree to which the system can be

adjusted to changes in processing requirements due to such
factors as changes in product or service design, changes in
volume processed and changes in technology

How much variety

What degree of
in products or What is the
equipment
services will the expected volume
flexibility will be
system need to of output
needed
handle
PROCESSSELECTION(CONTD.)

Facilities and
Forecasting Capacity Equipment
Planning

Product and Layout

Service Design

Process
Selection
Technological Work Design
Change
PROCESSTYPES
JOBSHOP
◦ A job shop usually operates on a relatively small scale. It is
used when a low volume of high variety goods or service will
be needed.
◦ Here processing is intermittent – work includes small jobs,
each with different processingrequirements
◦ High flexibility using general purpose equipment andskilled
workers are important characteristics of a job shop

Organization producing state of the art tools

Hospital medical service
PROCESSTYPES(CONTD.)
BATCH
◦ Batch processing is used when a moderate volume of goods or
services is desired. Also it can handle a moderate variety in
products or services
◦ The equipment need not be as flexible as in a job shop but
processing is still intermittent
◦ The skill level of workers does not need to be as high as ina
job shop because there is less variety in the jobs

Bakeries which make bread, cakes, cookies in batches

Plane carrying batches of people from airport to airport
Class room lecture, Concerts, Televisionprograms
PROCESSTYPES(CONTD.)
REPETITIVE
◦ When higher volumes of more standardized goods or services
are needed, repetitive processing is used. Standardized output
means only slight flexibility of equipment isneeded
◦ The requirement of skilled workers is generallylow

Manufacturing plants producing pencils, television sets etc.

Automatic carwash, cafeteria lines etc.
PROCESSTYPES(CONTD.)
CONTINUOUS FLOW
◦ When a very high volume of nondiscrete, highly standardized
output is desired, a continuous system is used
◦ These systems have almost no variety in output and henceno
need for equipment flexibility
◦ Highly specialized equipment can turn down the requirement
of expert worker

Factory producing sugar, flour, steel, salt

Internet service
PROCESSTYPES(CONTD.)
PROJECT
◦ A nonrepetitive set of activities directed toward a unique goal
within limited time frame
◦ A project is used for work that is nonroutine, with a uniqueset
of objectives to be accomplished in a limited time frame
◦ Equipment flexibility and worker skill can range fromlow to
high

Building a dam, making a motion picture,

Launching a new product or service
Process types
Product – Process Matrix

The diagonal of the matrix

represents the ideal choice
of processing system for a
given set of circumstances.
Functions/activities affected by process choice
AUTOMATION
◦ Automation is machinery that has sensing and control devices
that enable it to operate automatically
◦ Automation can range from factories that are completely
automated to a single automated operation. Now a days
service is also enjoying automation. For example, Bank ATM
system
◦ Automation offers a number of advantages over humanlabor
◦ It has low variability whereas it is difficult for a human to
perform a task in exactly the same way, in the same
amount of time
◦ Machines do not get bored or distracted, nor they go out
on strike, ask for higher wages or forlabor grievances
AUTOMATION (CONTD.)
◦ Automation is frequently pushed as a strategy necessary for
cost competitiveness
◦ Automation also offers a number of disadvantages over
human labor
◦ Technology is very expensive, usually it requires high
volumes of output tooffset high costs
◦ Automation is much less flexible. Once the process has
been automated, there is substantial reason for not
changing it

Careful planning is necessary to successfully integrate automation into

a productionsystem
Manufacturing cell, N/C machine, FMS
TYPESOFAUTOMATION
FIXED AUTOMATION
◦ It is the most rigid type automation. Sometimes referred as
Detroit type automation

◦ It uses low cost, specialized equipment for a fixedsequence of

operations. Low cost and high volume production are its
primary advantages

◦ Minimal variety and the cost of making major changes in

either product or process are its primarylimitations
TYPESOFAUTOMATION(CONTD.)
PROGRAMMABLEAUTOMATION
◦ Programmable automation involves use of high cost, general
purpose equipment controlled by a computer program. The
computer provides both the sequence of operations and
specific details about eachoperation

◦ Ithas the capability of economically producing a fairly wide

variety of lowvolume products in small batches

Robot is a machine consisting of a mechanical arm, a

power supply and a controller. Robots can handle a wide
variety of tasks including welding, assembly, loading and
unloading of machines, painting andtesting.
TYPESOFAUTOMATION(CONTD.)
FLEXIBLE AUTOMATION
◦ Flexible Manufacturing System (FMS): A FMS is a group of
machines that include supervisory computer control,
automatic material handling and robots. This system can
produce a variety of similar products. Systems can range from
three or four machines tomore than a dozen

◦ Ithas the capability of reducing labor cost and maintain the

quality constantly
◦ It requires less capital investment and offers highflexibility
than fixed automation
◦ FMS helps to achieve both the flexibility of job shop
processing and productivity of repetitive processsystems
FACILITIES LAYOUT

◦ The configuration of departments, work centers, and

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

◦ Product layouts
◦ Process layouts
◦ Fixed-Position layout
◦ Combination layouts
OBJECTIVEOFLAYOUT DESIGN
◦ Facilitate attainment of product orservice quality
◦ Use workers and space efficiently
◦ Avoid bottlenecks
◦ Minimize unnecessary material handling costs
◦ Eliminate unnecessary movement of workers or materials
◦ Minimize production time or customer servicetime
◦ Design for safety
PRODUCTLAYOUT
◦ Layout that uses standardized processing operations to
achieve smooth, rapid, high-volume output

PROCESSLAYOUT
◦ Layout that can handle varied processing requirements
A U-Shaped Production Line

U-Shape layouts – it is more compact; it is often requires

approximately half the length of a straight production line.
- there is less need for teamwork and
communication.
Fixed-position layouts

• The product or project remains stationary and workers,

materials, and equipment are moved as needed.

• If weight, size, bulk, or some other factor makes it

undesirable or extremely difficult to move the product.

• E.g. firefighting, road-building, home-building, drilling for

oil etc.
Cellular layout

• Cellular in which machines are grouped into a cell that

can process items that have similar processing
requirements.
Flexible manufacturing systems
• FMS: a group of machnies designed to handle
intermittent processing requirements and produce a
variety of similar products.

• CIM (Computer Integrated Manufacturing): a system of

linking a broad range of manufacturing activities through
an integrating computer system
Service Layouts

• Warehouse and storage layouts

• Minimizing movement & picking time and cost.
• The design of storage facilities presents a different set of factors than
the design of factory layouts.

• Retail layouts
• Presence & influence of customers.
• It often pertains to cost minimization and product flow.

• Office layouts:
• Information is computerized, image of openness.
• Transformation as the flow of paper works is replaced with the
increasing use of electronic ommunication
Design Product Layouts: Line Balancing

• Line Balancing is the process of assigning

tasks to workstations in such a way that the workstations
have approximately equal time requirements.

• This way the idle time will be minimized, utilization will be

maximized.

Specialization: dividing work

into elemental tasks that can
be performed quickly and
routinely.
Cycle Time

• Cycle time is the maximum time allowed at each

workstation to complete its set of tasks on a unit.
Precedence Diagram
• A diagram that shows elemental tasks and their
precedence requirements.

0.1 min. 1.0 min.

A simplified precedence
a b diagram

c d e
0.7 min. 0.5 min. 0.2 min.
Line balancing procedure
Other approaches
• Paralell workstations

• Cross-train workers (dynamic line balancing)

• Mixed model line

(more product on the same line)
Parallel Workstations

1 min. 30/hr. 1 min. 30/hr. 2 min. 30/hr. 1 min. 30/hr.

Bottleneck
2 min. 30/hr.
30/hr.
1 min. 60/hr. 1 min. 1 min. 60/hr.
30/hr.
2 min. 30/hr.
Parallel Workstations 1 min.
on average
Closeness Ratings

1. Use same equipment or facilities

2. Share the same personnel or records
3. Sequence of work flow
4. Ease of communication
5. Unsafe or unpleasant conditions
6. Similar work performed
Thank you for your
attention