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McGraw-Hill/Irwin Copyright © 2009 by The McGraw-Hill Companies, Inc. All Rights Reserved.

Chapter 6

Process Selection and Facility Layout

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Chapter 6: Learning Objectives

You should be able to: ± Understand the strategic importance of process selection ± Explain the effects of process selection on the organization ± Describe the basic processing types ± Discuss process automation ± Explain the need for management of technology ± List some reasons for redesign of layouts ± Describe the basic layout types

± List the advantages and disadvantages of product and processlayout ± Solve simple line-balancing problems ± Develop simple process layouts

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Process Selection

Process selection ± Refers to the deciding on the way production of goods

or services will be organized

± It has major implications for Capacity planningLayout of facilitiesEquipment

Design of work systems

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T echnology

Technology ± T he application of scientific discoveries to the

development and improvement of products and

services and operations processesTechnological Innovation ± T he discovery and development of new or improved

products, services, or processes for producing or

providing them

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T echnology Acquisition

T echnology acquisition decisions must beweighed carefully ± What are the upside and downsides of the

technology? ± What can and can¶t a technology do? ± Economic considerations ± Integration considerations

± Human considerations

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Process Selection

1. Variety ± How much?

2. Equipment flexibility ± T o what degree?

3. Volume ± Expected output?

Job Shop

Repetitive

Batch

Continuos

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Automation

Automation ± Machinery that has sensing and control devices that

enable it to operate automatically

Fixed automationProgrammable automationFlexible automation

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Automation Questions

1. What level of automation is appropriate?2. How would automation affect system flexibility?3. How can automation projects be justified?

4. How should changes be managed?5. What are the risks of automating?6. What are the likely effects of automating on:

± Market share

± Costs ± Quality ± Customer satisfaction ± Labor relations ± Ongoing operations

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Automation T echnologies

Computer-Aided Manufacturing (CAM) ± T he use of computers in process control, ranging from robots to

automated quality control

Numerically Controlled (N/C) Machines ± Machines that perform operations by following mathematical

processing instructions

Robot ± A machine consisting of a mechanical arm, a power supply, and

a controller

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Facilities Layout

Layout ± the configuration of departments, work centers, and

equipment, with particular emphasis on movement of

work (customers or materials) through the system ± Facilities layout decisions arise when:

Designing new facilitiesRe-designing existing facilities

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Basic Layout T ypes

Product layouts

Process layouts

Fixed-Position layoutCombination layouts

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FMS and CIM

FMS (Flexible Manufacturing System)

± A group of machines designed to handle intermittent processingrequirements and produce a variety of similar products

CIM (Computer Integrated Manufacturing) ± A system for linking a broad range of manufacturing activities

through an integrated computer system

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Designing Product Layouts: Line Balancing

T he goal of a product layout is to arrange workers or machines inthe sequence that operations need to be performed

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Line Balancing

Line balancing ± T he process of assigning tasks to workstations in

such a way that the workstations have approximately

equal time requirements ± Why is line balancing important?

1. It allows us to use labor and equipment more efficiently.2. T o avoid fairness issues that arise when one workstation

must work harder than another.

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Designing Process Layouts

T he main issue in designing process layoutsconcerns the relative placement of thedepartments

Measuring effectiveness ± A major objective in designing process layouts is to

minimize transportation cost, distance, or time