Materials Handling
The central focus of most manufacturing layouts is to minimize the cost of processing, transporting, and storing materials throughout the production system. Materials used in manufacturing include: Raw material Purchased components Work-in-progress Finished goods Packaging material Maintenance, repair, and operating supplies
Materials Handling
A materials-handling system is the entire network of transportation that: Receives material Stores material in inventories Moves material between processing points Deposits the finished products into vehicles for delivery to customers
Materials Handling
Material-Handling Principles Move directly (no zigzagging/backtracking) Minimize human effort required Move heavy/bulky items the shortest distances Minimize number of times same item is moved MH systems should be flexible Mobile equipment should carry full loads
Materials Handling
Material-Handling Equipment Automatic transfer devices Containers/pallets/hand carts Conveyors Cranes Elevators Pipelines Turntables AGVS
Equipment that perform similar processes are grouped together Used when the operations system must handle a wide variety of products in relatively small volumes (i.e., flexibility is necessary)
General-purpose equipment is used Changeover is rapid Material flow is intermittent Material handling equipment is flexible Operators are highly skilled
Technical supervision is required Planning, scheduling and controlling functions are challenging Production time is relatively long In-process inventory is relatively high
Operations are arranged in the sequence required to make the product Used when the operations system must handle a narrow variety of products in relatively high volumes Operations and personnel are dedicated to producing one or a small number of products
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Special-purpose equipment are used Changeover is expensive and lengthy Material flow approaches continuous Material handling equipment is fixed Operators need not be as skilled
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Little direct supervision is required Planning, scheduling and controlling functions are relatively straight-forward Production time for a unit is relatively short In-process inventory is relatively low
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Operations required to produce a particular family (group) of parts are arranged in the sequence required to make that family Used when the operations system must handle a moderate variety of products in moderate volumes
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Equipment can be less general-purpose Material handling costs are reduced Training periods for operators are shortened In-process inventory is lower Parts can be made faster and shipped more quickly
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Equipment can be less special-purpose Changeovers are simplified Production is easier to automate
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Fixed-Position Layouts
Product remains in a fixed position, and the personnel, material and equipment come to it Used when the product is very bulky, large, heavy or fragile
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Hybrid Layouts
Actually, most manufacturing facilities use a combination of layout types. An example of a hybrid layout is where departments are arranged according to the types of processes but the products flow through on a product layout.
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Designed for quality Designed for flexibility - to quickly shift to different product models or to different production rates Cellular layout within larger process layouts Automated material handling U-shaped production lines
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More open work areas with fewer walls, partitions, or other obstacles Smaller and more compact factory layouts Less space provided for storage of inventories throughout the layout
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Cell Formation Decision Which machines are assigned to manufacturing cells Which parts will be produced in each cell
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Fundamental Requirements for Parts to be Made in Cells Demand for the parts must be high enough and stable enough that moderate batch sizes of the parts can be produced periodically. Parts must be capable of being grouped into parts families.
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Cell Formulation Maxx produces superchargers for high performance cars and trucks. Maxx has implemented a group technology program in its shop and now must formulate the manufacturing cells. Maxx has identified six parts that meet the requirements for CM. The parts-machines matrix on the next slide identifies the 6 parts and 5 machines on which the parts are presently produced.
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2
X X X
3 X
4
X X
5 X X
6 X
Machines
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3 X X
5 X X
6 X X
Machines
X X
X X X
X X X
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3 X X
5 X X
6* X X
Machines
X X
X X X
X X
* exceptional part
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2 manufacturing cells (MC1, MC2) will be used. Parts 3 and 5 will be produced in MC1 on machines A and E. Parts 1, 2 and 4 will be produced in MC2 on machines B, C and D. Part 6 is an exceptional part that cannot be produced within a single cell.
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Characteristics of Services
There may be a diversity of services provided There are three dimensions to the type of service: Standard or custom design Amount of customer contact Mix of physical goods and intangible services There are three types of service operations:
Quasi manufacturing operations: Kitchen area of Fast Food Restaurant Customer-as-Participant: ATM, Dept. stores or Fast Food Restaurant Customer-as-Product: hair salons, medical clinics, hospitals, tailors
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The encounter between the customer and the service must be provided for. The degree to which customer-related features must be provided varies with the amount of customer involvement and customer contact.
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For many service operations, layouts are like process layouts in manufacturing The departments of hospitals are grouped and located according to their processes In some cases, closeness ratings are used to reflect the desirability of having one department near another
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Develop layout with dept. pairs idenStep 3 tified in Step 2 adjacent to one another.
Let m = m + 1 and n = n - 1.
No Does m = 3 and n = 4 ? Yes Stop
Identify dept. pairs with CR of n. Fit the dept. pairs identified in Step 4 into the trial layout from Step 3. Examine the trial layout from Step 5. If any CRs of dept. pairs are violated, rearrange depts. to comply with CRs.
Step 4 Step 5
Step 6
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Typical Closeness Ratings Closeness Rating 1 2 3 4 5 6 Meaning of Rating Necessary Very Important Important Slightly Important Unimportant Undesirable
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Example: AG Advertising
Using Closeness Ratings AG Advertising is moving into a new office suite having seven large, roughly equal size rooms, one for each department of the firm. Lisa, the manager, must now assign each department to a room. She has developed a grid of closeness ratings (on the next slide) for the 21 unique pairs of departments.
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Example: AG Advertising
Closeness Ratings Grid Dept. A Dept. B Dept. C Dept. D Dept. E Dept. F Dept. G
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6 4 2
6 3
1
4 5
2
1 1
4
2 3
5
2
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Example: AG Advertising
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Example: AG Advertising
B F
D C G
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Example: AG Advertising
Trying to satisfying all pairings of departments with 6 closeness ratings, we see that Dept. C needs to be moved. CR = 1 BD BF CG
B F
D G C
CR = 6 AD BC
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Example: AG Advertising
Layout Satisfying All Pairings of Departments with 6 Closeness Ratings (note that we swapped Dept. D and Dept. F) CR = 1 BD BF CG
B D
F E
A G C
CR = 6 AD BC
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Strive for flexibility in layouts Multi-job training of workers Sophisticated preventive-maintenance programs Flexible machines Empowered workers trained in problem solving Layouts small and compact Services follow the above practices plus incorporate customer needs in design
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