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2.0 Process Selection and Facility Layout

The document discusses process selection and facility layout. It describes different types of processes - job shop, batch, repetitive, and continuous - based on the variety and volume needs. It also covers basic facility layout systems like product layout and process layout. Product layout is used for high volume, standardized output while process layout handles varied processing. The advantages and disadvantages of each layout type are provided.

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Shanthiyaah Arumugam
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© © All Rights Reserved
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37 views

2.0 Process Selection and Facility Layout

The document discusses process selection and facility layout. It describes different types of processes - job shop, batch, repetitive, and continuous - based on the variety and volume needs. It also covers basic facility layout systems like product layout and process layout. Product layout is used for high volume, standardized output while process layout handles varied processing. The advantages and disadvantages of each layout type are provided.

Uploaded by

Shanthiyaah Arumugam
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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2.

0 PROCESS
SELECTION &
FACILITY
LAYOUT
Organizing Production of Good and Services
• Process selection
• Deciding on the way production of goods or services will be organized
• Major implications
• Capacity planning
• Layout of facilities
• Equipment
• Design of work systems
Process Selection
The two key questions in process selection
are:
1. How much variety will the process
need to be able to handle?
2. How much volume will the process need
to be able to handle?
Basic Facility Layout
Type of Processing
Process Type: Job Shop
• Job Shop. A job shop usually operates on a relatively small scale. It is
used when a low volume of high-variety goods or services will be
needed. High flexibility using general-purpose equipment and skilled
workers are important characteristics of a job shop. A manufacturing
example of a job shop is a tool and die shop that is able to produce
Process Type: Batch
• Batch. Batch processing is used when a moderate volume of goods or
services is desired, and 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 doesn’t
need to be as high as in a job shop because there is less variety in the
jobs being processed.
• Examples of batch systems include bakeries, which make bread, cakes,
or cookies in batches ;movie theaters, which show movies to groups
(batches) of people; and airlines, which carry plane loads (batches) of
people from airport to airport. paint, ice cream, soft drinks, beer,
magazines, and books.
• Other examples of services include plays, concerts, music videos,
Process Type: Repetitive
• Repetitive. When higher volumes of more standardized goods or services
are needed,repetitive processing is used. The standardized output means
only slight flexibility of equipmentis needed.
• Skill of workers is generally low. Examples of this type of system
includeproduction lines and assembly lines. In fact, this type of process is
sometimes referred to as assembly.
• Familiar products made by these systems include automobiles, television
sets, pencils, and computers. An example of a service system is an
automatic carwash. Other examples of service include cafeteria lines and
ticket collectors at sports events and concerts. Also, mass customization is
an option.
Process Type Continous
• Continuous. When a very high volume , highly standardized output is
desired, a continuous system is used. These systems have almost no
variety in output and, hence, no need for equipment flexibility.
Workers’ skill requirements can range from low to high, depending on
the complexity of the system and the expertise workers need.
Generally, if equipment is highly specialized, worker skills can be
lower
• These process types are found in a wide range of manufacturing and
service settings
Comparison
Process Selection: Management
Technology
• Technology and technological innovation often have a major
influence on business processes. Technological innovation refers to
the discovery and development of new or improved products,
services, or processes for producing or providing them
• RFID, IT, Barcode scanner, Automation , Robotics
• Computer-aided manufacturing (CAM)
• Computerized numerical control (CNC).
• Flexible manufacturing system (FMS)
• Computer-integrated manufacturing (CIM)
• Factory 4.0 IOT
Basic Layout System : Conveyor
Basic Layout System : Cell Production
• Cell production is a form of team working and helps ensure worker
commitment, as each cell is responsible for a complete unit of work,
which Herzberg would view as part of job enrichment.
Basic Layout System : Semi Automation
System
A  machine or machine tool with a partially automated work cycle
A semiautomatic machine can be fully automated with the addition of certain special
devices. The partially automated work cycle is widely used in various types of modern machines, 
particularly in those designed for series production processes. 
Basic Product Layout System (Repetitive)

• Product layouts are used to achieve a smooth and rapid flow of large
volumes of goods or customers through a system. This is made possible
by highly standardized goods or services that allow highly standardized,
repetitive processing. The work is divided into a series of standardized
tasks, permitting specialization of equipment and division of labor.
• In manufacturing environments, the lines are referred to as production
lines or assembly lines, depending on the type of activity involved
U Shaped Layout
• U-Shaped Layouts. Although a straight production line may have intuitive appeal,
aU-shaped line has a number of advantages that make it worthy of consideration.
• One disadvantage of a long, straight line is that it interferes with cross-travel
ofworkers and vehicles.
• A U-shaped line is more compact; it often requires approximately half the length of
a straight production line. In addition, a U-shaped line permits increased
communication among workers on the line because workers are clustered, thus
facilitating Workers tea,work .
• Flexibility in work assignments is increased because workers can handle not only
adjacent stations but also stations on opposite sides of the line. Moreover, if
materials enter the plant at the same point that finished products leave it, a U-
shaped line minimizes material handling
Process Layout(Nonrepetitive Processing)
• Process layouts (functional layouts) are designed to process items or
provide services that involve a variety of processing requirements.
The variety of jobs that are processed requiresfrequent adjustments
to equipment
• Process layouts are quite common in service environments. Examples
include hospitals,colleges and universities, banks, auto repair shops,
airlines, and public libraries
Classify The Design Process Layout

• Fixed-Position Layouts In fixed-position layouts, the item being worked on


remains stationary, and workers, materials, and equipment are moved about as
needed.
• Combination Layouts
• Cellular Production. Cellular production is a type of layout in which workstations
are grouped into what is referred to as a cell. Groupings are determined by the
operations needed to perform work for a set of similar items, or part families,
that require similar processing
• Service Layouts
• Warehouse and Storage Layouts
• Retail Layouts
• Office Layouts.
• Restaurant Layouts
• Hospital Layouts.
• Automation in Services.
Advantages and Disadvantages
Between Process Layout and Product Layout
System
Advantages and Disadvantages of Product Layout
Advantages: Disadvantages:
• The intensive division of labor usually creates
• A high rate of output. dull, repetitive jobs that provide little
opportunity for advancement and may lead to
• Low unit morale problems and to repetitive stress
• Labor specialization injuries.
• Poorly skilled workers may exhibit little
• Low material-handling cost per interest in maintaining equipment or in the
unit. quality of output.
• A high uti • The system is fairly inflexible in response to
changes in the volume
• The establishment of routing and • The system is highly susceptible to shutdowns
scheduling in the initial design • Preventive maintenance, the capacity for
quick repairs, and spare-parts inventories
• Fairly routine accounting,
• Incentive plans tied to individual output are
purchasing, and inventory control impractical since they would cause variations
among outputs of individual workers
Advantages and Disadvantages of Process Layout
Disdvantages:
• In-process inventory costs can be high if
Advantages: batch processing is used
• Routing and scheduling pose continual
• Systems can handle a variety of challenges.
processing • Equipment utilization rates are low.
• systems are not particularly • Material handling is slow and inefficient, and
more costly per unit than in product layouts.
vulnerable to equipment failures
• Job complexities often reduce the span of
• General-purpose equipment is supervision and result in higher supervisory
often less costly than the costs than with product layouts
specialized equipment used in • Special attention necessary for each product
or customer (e.g., routing, scheduling,
product layouts and is easier and machine setups) and low volumes result in
less costly to maintain. higher unit costs than with product layouts.
• It is possible to use individual • Accounting, inventory control, and
purchasing are much more involved than
incentive systems. with product layouts.

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