Facility Planning
How is a manufacturing facility planned?
Manufacturing Facilities
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What are the major tasks in organizing a
manufacturing facility?
What is the role of a manufacturing engineer?
What is an operations process chart?
What is a flow process chart?
Group Activity
You have been hired by ABC company as a
manufacturing engineer. Your jobs is to decide
how to efficiently manufacture your class project.
You have 5 minutes to discuss the product and think about
how to produce it. Remember to incorporate your jigs
and fixtures. Prepare a brief 2-3 minutes presentation
for the class.
Manufacturing Facilities
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Manufacturing takes place in a manufacturing facility.
Manufacturing Engineers design and develop manufacturing
facilities. They have 5 major tasks:
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Operation Selection
Material Handling Study
Tooling Design
Plant Layout
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Efficiency Studies
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The GOAL is to produce the product at a competitive price. (a
price similar to products like it on the market)
Task 1:
Selecting and Sequencing Operations
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While hiring good employees and getting the right
equipment is important, they must still be employed
wisely.
The engineer must select (decide which process must
be done) and sequence (put them in the most
efficient order).
Several forms and methods are used to do this.
Operations Sheet
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What operations are used to shape the product
and what processes are used?
The following items are recorded on an operations
sheet:
 Operation
name
 Machine used
 Tooling needed
Flow Process and
Operation Process Charts
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As a product is manufactured, parts must be
transferred to various placed and in some cases
stored.
The order of these steps and process is an
important part of the manufacturing process.
Two forms are used to place manufacturing tasks in
order:
 Flow
Process Chart
 Operation Process Chart
Flow Process Chart
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Show a the step-by-step process
for producing a single part.
 Describes the task
 Provides a code number for
each task
 Identifies the machines used
 Lists tooling needed for the
task
Standard symbols are used to
identify each task that were
developed by the American
Society of Mechanical Engineers
(ASME)
Process Flow Chart Symbols
Operation
Object is changed
in its chemical or
physical makeup; it
is assembled or
disassembled
Transportation
Object has moved
from one place to
another
Inspection
Object is checked
against quality
standards
Delay
Storage
Object is held for
the next operation
Object is placed in
a protected
location
Example: Flow Process Chart
Group Activity
Divide into groups of 3-4 members.
Using the worksheets given, create a flow
process chart for the class project.
Operation Process Chart
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An operation process chart shows how each part is
made and then show the assembly of the product.
Transportation, delay, and storage tasks are not
included in the chart.
The operations process chart is used in scheduling
production. It shows what parts need to be finished
at what time frame. This reduces the storage
needed.
JIT- “Just is time” – parts arrive just in time for
assembly. This helps reduce costs.
Example: Operation Process Chart
PLASTIC
CLIP
1. Cut to width
2. Cut to length
3. Drill holes
4. Round corners
5. Assemble to clip
Group Activity
In your groups of 3-4 members…
On the back of your Flow Process Chart worksheets,
create an operation process chart for the class project.
Use your flow process charts to help you outline your
steps.
You have 10 minutes to prepare your flow charts. Prepare a 2-3
minutes presentation for the class.
Task 2: Designing Tooling
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Tooling: devices such as jigs, fixtures, patterns, and
templates that help workers make products better
and faster.
Tooling is designed for three purposes:
 Increase
production speed
 Increase accuracy – less waste
 Increase safety
Task 3: Preparing Plant Layout
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Resource flow: moving materials and people through the facility
efficiently
Things to consider in the layout:
 Restroom location
 Break rooms
 Emergency Evacuations
The plan must include:
 Where to place machines
 How to move material
 Where to have aisles
 Where to locate utility systems (electricity, water, gas, etc.)
2 Types of Plant Layout
 Process Layout
 Product Layout
Process Layout
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Groups machines by the
processes they perform.
Most common in custom
manufacturing and
intermittent manufacturing
A plant can produce a
number of different
products and machines can
be used for a variety of
tasks.
Receiving
Dept. F
Dept. E
Dept. A
Dept. G
Dept. D
Dept. B
Dept. H
Dept. C
Shipping
Product Layout
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Places machines according
to the sequence of
operations.
Used in continuous
manufacturing plants
The machine needed for
the most operations is
placed near the storage
area. The machine needed
second is next and so on.
Several shapes are used
for continuous process lines.
Straight
Circular
S-Shaped
U-Shaped
Random
Task 4: Material Handling Systems
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Material handling – moving materials and products
through a facility
2 types of material handling:
 Fixed
path device –
 Items
always travel on the same path
 Assembly lines
 Examples: pipes, chutes, conveyors, etc.
 Variable
 Can
path device
be steered and move in various directions
 Examples: forklifts, overhead cranes, tractors, trucks, etc.they require an operator
Task 5:
Improving Manufacturing Systems
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Production lines can be redesigned
Operations can be redesigned
Efficiency can be evaluated
More efficient tools or machines can be used
Group Activity - Reflection
You have been hired by ABC company as a
manufacturing engineer. Your jobs is to decide
how to efficiently manufacture your class project.
Look back at the task (listed above) that you did at the
beginning of this unit. How has your views of a
manufacturing facility changed? (write a paragraph
reflection in your class notebook.)
Review: Manufacturing Facilities
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What are the major tasks in organizing a
manufacturing facility?
What is the role of a manufacturing engineer?
What is an operations process chart?
What is a flow process chart?