Chapter 3 Module A

Flow Analysis Techniques

Learning Objectives
• Understand the importance of material flow and flow analysis
• Be able to identify and construct various flow analysis tools
• Be able to calculate flow efficiency by the use of a from-to chart
Flow Analysis
• The heart of plant layout and the beginning of the material handling
plan
• Flow analysis determines the path that every part takes through the
plant, which minimizes
• distance traveled (measured in feet),
• backtracking,
• cross traffic,
• cost of production.
Flow Analysis
• Flow analysis will assist the manufacturing facilities designer in the
selection of the most effective arrangement of machines, facilities,
workstations, and departments.

• Improved product flow means increase in profitability.

Flow Routing
• To establish this best arrangement of equipment, facilities designers
use four techniques:
• String diagram
• Multicolumn process chart
• From-to chart
• Process chart
Ex. Flow Routing
• 5 part-8 workstation layout.
• 5 parts: 1, 2, 3, 4, 5;
• 8 workstations: R, A, B, C, D, E, F, S.
String Diagram
• Circles represent the equipment and the lines between circles
indicate flow
• Flow lines between adjacent circles are from middle of circle to
middle of circle
• If you jump a department, you will place the line above the circles
• If the flow is backward, called backtracking (going toward R), the flow
line is drawn under the circles
String Diagram
String Diagram: Improved
String Diagram: Efficiency

Number of Steps = ???

Efficiency (Existing) = ???
Efficiency (Improved) = ???
Multicolumn Process Chart
• A routing planning chart that shows the sequence of operations of
each part number against each other in separate column.
• It uses the same routing information as used in string diagram, but in
different view.
Multicolumn Process Chart
From-To Chart
• The from-to chart is the most exact technique of the three.
• Provides information concerning the number of material handling
trips between departments (work center)
• The from-to chart is sometimes called a cross chart, and when
distance is added to the values, it is termed a travel chart.
• The from-to chart is a matrix. The sequence of operations is written
down the left-hand side of the form and across the top.
From-To Chart
Relative Importance
• Each part are equally important and the quantity and weight of each
part was recorded.
From-To Chart: Efficiency

Compute for efficiency (existing).

Efficiency (improved) = ???
From-To Chart: Penalty Points

Forward = multiple by 1
Backtrack = multiple by 2
Machine Sequencing
• Machining centers (departments) are laid out in such way that the
total forward flows on the line is maximized, or total backward flows
are minimized.
• Hollier developed two heuristic algorithms that can achieve ordering
of machines for minimizing backtrack flows
Hollier Method
• Step 1: Develop the “From-To” chart from part routing data. The data
contained in the chart indicates numbers of parts moves between
machines (or work stations) in the cell. Moves into and out of the cell
are not included in the chart.

• Step 2: Determine the “From” and “To” sums for each machine. This
is accomplished by summing all of the “From” trips and “To” trips for
each machine.
Hollier Method
• Step 3: Assign machines to the cell based on minimum “From” or “To”
sums. The machine having the smallest sum is selected. If the
minimum value is a “To” sum, then the machine is placed at the
beginning of the sequence. If the minimum value is a “From” sum,
then the machine is placed at the end of the sequence.
• Step 4: Reformat the From-To chart. After each machine has been
selected, restructure the From-To chart by eliminating the row and
column corresponding to the selected machine and recalculate the
“From” and “To” sums.
• Step 5: Repeat steps 3 and 4 until all machines have been assigned.
Total Plant Flow
• Three techniques
• Flow Diagram
• Operation Process Chart
• Flow Process Chart