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Facilities and
Forecasting Capacity Equipment
Planning
Process
Technological Selection Work
Change Design
Process Selection
Batch
Variety
How much
Job Shop Repetitive
Flexibility
What degree
Volume
Continuous
Expected output
Types of Operations
INCREASED VOLUME
Process Design
Project Processes (Fixed Position)
Intermittent Flow Processes (Batch
Shops)
Continuous Flow Processes (Flow
Shops)
Processing Industries (Continuous)
Job Shop (Fixed Position)
People and material move
Have limited duration
Small scale
Examples
Housing
Ship building
Dam
Appliance Repair
Intermittent Flow Processes
(Batch Shops)
No pattern exists between process of
different products
Appropriate to service organizations
Moderate volume
Example:
Machine Shops
Auto Repair Shops
Commercial Bakery
Classroom Lecture
Continuous Flow Processes
(Flow Shops)
Sequences are the same (Standard
Routes)
High volumes of standardized goods or
services
Examples:
Assembly Lines
Car Wash
Processing Industries (Continuous
Flow)
One primary input (gas, wheat, etc) is
converted to multiple outputs
Very high volumes of non-discrete
goods
Example:
Petroleum
Chemicals
Food Industries
Process Characteristics
Raw
Station Station Station Station Finished
materials 1 2 3 4 item
or customer
Material Material Material Material
and/or and/or and/or and/or
labor labor labor labor
0.8 0.6
c d f g h
1.0 0.4 0.3
Solution to Example 2
a b e
f g h
c d
A U-Shaped Production Line
In 1 2 3 4
Workers
Out 10 9 8 7
Process Layout (functional)
Assume we have the following
departments:
Accounting (A)
Production Planning (P)
Customer Service (C)
Sales (S)
What arrangement would be better?
Used for Intermittent processing
Job Shop or Batch
A P S C
C S A P
Intermittent Process
Criteria
Desirability ranking
Volume of interaction
Cost of interaction
Distance
Time
Safety
Facility Limitations
Advantages of Process Layouts
Can handle a variety of processing
requirements
Not particularly vulnerable to equipment
failures
Equipment used is less costly
Possible to use individual incentive plans
Disadvantages of Process Layouts
In-process inventory costs can be high
Challenging routing and scheduling
Equipment utilization rates are low
Material handling slow and inefficient
Complexities often reduce span of
supervision
Special attention for each product or
customer
Accounting and purchasing are more
involved
Cellular Layouts
Cellular Production
Layout in which machines are grouped into a
cell that can process items that have similar
processing requirements
Group Technology
The grouping into part families of items with
similar design or manufacturing
characteristics
Process Layout - Example
Milling
Assembly
Grinding
& Test
Drilling Plating
Process Layout - work travels
to dedicated process centers
Functional Layout
111 111
Heat 111 Gear
333 Lathes
treat cutting 444
Cellular Manufacturing Layout –
Group Technology
Heat Gear
-1111 Lathe Mill Drill -1111
treat cut
Heat
Assembly
222222222 Mill Drill Grind - 2222
treat
Heat
3333333333 Lathe Mill Grind - 3333
treat