1. Process and Material Flow Analysis Chapter 3

2. Data requirement for layout decisions • Frequency of trips or flow of material or some other measure of interaction between departments • Shape and size of departments • Floor space available • Location restrictions for departments, if any • Adjacency requirements between pairs of departments, if any

3. Flow pattern at 800-acre Nissan plant in Smyrna, TN

4. Possible flow patterns

5. Dendrite flow pattern

6. Spine flow pattern

7. Five types of layout • Product layout • Process layout • Fixed-position layout • Group-technology layout • Hybrid layout

8. Types of Departments/Layouts Volume High Medium Low Product Department Product Layout Product Family Department Fixed Location Layout Process Layout Group Technology Layout Fixed Materials Location Department Process Department Low Medium High Variety

9. Product layout

10. Product Layouts Product A Department D D M G P D A Product B Department Receiving Department L L M M D G P A Shipping Department Product C Department L L L G G P A

11. Process layout

12. Milling Department Lathe Department Drilling Department M M D D D D L L M M D D D D L L G G G P L L G G G P L L Painting Department Grinding Department L L A A A Receiving and Shipping Assembly The Process Layout

13. Milling Department Lathe Department Drilling Department M M D D D D L L M M D D D D L L G G G P L L G G G P L L Painting Department Grinding Department L L A A A Receiving and Shipping Assembly Flow of Materials in Process Layouts

14. Group technology layout

15. G G G D D D L L D M G D L L G M D L Rotational Parts Cell L P L M D P L Rectangular Parts Cell G M L A Special Department A Receiving and Shipping Product Family (Cellular) Layout Source: John S. Usher class notes

16. HM VM Worker 3 VM Paths of three workers moving within cell Material movement L Direction of part movement within cell Worker 2 G L Key: S = Saw L = Lathe HM = Horizontal milling machine VM = Vertical milling machine G = Grinder Final inspection Finished part S Worker 1 Out In A Manufacturing Cell Source: John S. Usher class notes

17. Project (Fixed-Position) Layout G G D D D L G L G Storage Storage L A L A M P Receiving and Shipping Source: John S. Usher class notes

18. Hybrid layout

19. TM TM TM TM TM Hybrid Layouts • Combination of the layouts discussed. • A sample hybrid layout that has characteristics of group, process and product layout is shown in the following figure. • A combination of group layout in manufacturing cells, product layout in assembly area, and process layout in the general machining and finishing section is used. DM BM

20. General Characteristics

21. Exercise – What Type of Layout? • Assembly Plant ___________ • Meijers ___________ • Suburban Hospital ___________ • International Airport ___________ • Restaurant ___________ • Boeing Aircraft ___________

22. Automated Manufacturing Cell

23. Flexible Manufacturing Systems • Automated machining operations, tool changers • Automated material handling, computer control • Designed around size of parts processed & average processing time for parts • Can process wide variety of items quickly • Very few large systems exist • Progressive layout – all parts same route • Closed loop – larger variety, alternative routes • Ladder layout – two machines work on same part • Open field layout – most complex