Manufacturing Process Layout
Lathe Department
L
L
L
L
L
L
L
L
L
L
Milling
Department
Drilling Department
M
M
D
D
D
D
M
M
D
D
D
D
G
G
G
P
G
G
G
P
Grinding
Department
Receiving and
Shipping
Painting Department
A
A
A
Assembly
Slide 0 of 96
Process (Job Shop) Layouts


Equipment that perform similar processes are
grouped together
Used when the operations system must handle a wide
variety of products in relatively small volumes (i.e.,
flexibility is necessary)
Slide 1 of 96
Characteristics of Process Layouts


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General-purpose equipment is used
Changeover is rapid
Material flow is intermittent
Material handling equipment is flexible
Operators are highly skilled
. . . more
Slide 2 of 96
Characteristics of Process Layouts
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
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Technical supervision is required
Planning, scheduling and controlling functions are
challenging
Production time is relatively long
In-process inventory is relatively high
Slide 3 of 96
A Product Layout
In
Out
Slide 4 of 96
Product (Assembly Line) Layouts



Operations are arranged in the sequence required to
make the product
Used when the operations system must handle a
narrow variety of products in relatively high volumes
Operations and personnel are dedicated to producing
one or a small number of products
Slide 5 of 96
Characteristics of Product Layouts

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Special-purpose equipment are used
Changeover is expensive and lengthy
Material flow approaches continuous
Material handling equipment is fixed
Operators need not be as skilled
. . . more
Slide 6 of 96
Characteristics of Product Layouts


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Little direct supervision is required
Planning, scheduling and controlling functions are
relatively straight-forward
Production time for a unit is relatively short
In-process inventory is relatively low
Slide 7 of 96
Comparison of Product
and Process Layouts
Product

Description

Type of process

Product


Demand
Volume
Equipment



Process

Sequential arrangement
of activities

Functional grouping
of activities

Continuous, mass
production, mainly
assembly
Standardized, made to
stock
Stable
High
Special purpose

Intermittent, job shop,
batch production,
mainly fabrication
Varied, made to order






Fluctuating
Low
General purpose
Slide 8 of 96
Comparison of Product
and Process Layouts
Product
Workers
Inventory



Storage space
Material handling
Aisles
Scheduling
Layout decision
Goal

Advantage














Limited skills
Low in-process, high
finished goods
Small
Fixed path (conveyor)
Narrow
Line balancing
In-l,ine, U-type
Equalize work at each
station
Efficiency
Process









Varied skills
High in-process, low
finished goods
Large
Variable path (forklift)
Wide
Dynamic
Functional
Minimize material
handling cost
Flexibility
Slide 9 of 96
Cellular Manufacturing (CM) Layouts
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Grouping of machines in cells
Each cell results in the production of particular part family.
Similar parts are identified and grouped together.
Similarity can be either in shape,size or in manufacturing
process
Operations required to produce a particular family (group) of
parts are arranged in the sequence required to make that family
Used when the operations system must handle a moderate
variety of products in moderate volumes
Slide 10 of 96
Part families
Part families with similarity
in manufacturing process
Part families with similarity
in shape
Slide 11 of 96
Original Process Layout
Assembly
4
6
7
8
5
2
A
B
12
10
3
1
9
C
11
Raw materials
Slide 12 of 96
Part Routing Matrix
Parts
1
2
A
B
C
D
E
F
G
H
x
x
3
Machines
4 5 6 7
8 9 10 11 12
x
x
x
x
x
x
x
x
x
x
x
x
x
x x
x
x
x
x
x
x
x
x
x
x
x
x
x
Figure 5.8
Slide 13 of 96
Reordered Routing Matrix
Parts
1
2
4
Machines
8 10 3 6
A
D
F
C
G
B
H
E
x
x
x
x
x
x
x
x
x x
x x
x
x
x
x
x
9 5
x
x
x
x
7 11 12
x
x
x
x
x
x
x
x
x
Slide 14 of 96
Revised Cellular Layout
Assembly
8
10
9
12
11
4
Cell 1
Cell 2
6
Cell 3
7
2
1
3
5
A B C
Raw materials
Slide 15 of 96
Automated Manufacturing Cell
Source: J. T. Black, “Cellular
Manufacturing Systems Reduce Setup
Time, Make Small Lot
Production Economical.” Industrial
Engineering (November 1983)
Slide 16 of 96
Characteristics of CM
Relative to Process Layouts

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

Equipment can be less general-purpose
Material handling costs are reduced
Training periods for operators are shortened
In-process inventory is lower
Parts can be made faster and shipped more quickly
Equipment can be less special-purpose
Changeovers are simplified
Production is easier to automate
Slide 17 of 96
Flexible Manufacturing Systems (FMS)



FMS consists of numerous programmable machine tools
connected by an automated material handling system and
controlled by a common computer network
FMS combines flexibility with efficiency
FMS layouts differ based on

variety of parts that the system can process

size of parts processed

average processing time required for part completion
Slide 18 of 96
Full-Blown FMS
Slide 19 of 96