The document discusses process design and facility layout. It describes different types of production layouts like flow lines, U-shaped lines, and cellular layouts. It then covers line balancing, which involves assigning tasks to workstations to equalize workloads. An example of line balancing for a fruit snack production line is provided, where the tasks are assigned to three workstations with an 83.3% efficiency level.

1. Process Design
and Facility Layout
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)
DMA Kulasooriya
ISL- Certified Six Sigma Black Belt

2. Cellular Layouts
 Cellular Manufacturing
 Group Technology
 Flexible Manufacturing Systems
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

3. A Flow Line for Production or
Service
Flow Shop or Assembly Line Work Flow
Raw
materials
or customer
Finished
item
Station
2
Station
3
Station
4
Material
and/or
labor
Statio
n
1
Material
and/or
labor
Material
and/or
labor
Material
and/or
labor
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

4. A U-Shaped Production Line
1 2 3 4
5
6
78910
In
Out
Workers
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

5. Cellular Manufacturing Layout
-1111 -1111
222222222 - 2222
Assembly
3333333333 - 3333
44444444444444 - 4444
Lathe
Lathe
Mill
Mill
Mill
Mill
Drill
Drill
Drill
Heat
treat
Heat
treat
Heat
treat
Gear
cut
Gear
cut
Grind
Grind
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

6. Design Product Layouts: Line
Balancing
Line Balancing is the process of
assigning tasks to workstations in such
a way that the workstations have
approximately equal time requirements.
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

7. Cycle Time
Cycle time is the maximum time
allowed at each workstation to
complete its set of tasks on a unit.
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

8. Line Balancing
Assembly line balancing operates under two constraints,
precedence requirements and cycle time restrictions’
Precedence requirements are expressed in the form of a
precedence diagram- network
Cycle time is calculated by dividing the time available for
production by the number of units to be produced – time
taken to completed item rolling off the assembly line.
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

9. Determine Maximum Output
O utput capacity =
O T
CT
O T operating tim e per day
D = Desired output rate
CT = cycle tim e =
O T
D

6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

10. Determine the Minimum Number
of Workstations Required:
Efficiency
stask timeofsum=t
CTDesired
t)(
=N


6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

11. Real fruit Snack are made from a mixture
of dried fruits and packaged. To meet
demand real fruit needs to produce 6000
fruit strips every 40-hour week. Design an
assembly line with fewest number of
workstations that will achieve the
production quota without violating
precedence constraints
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

12. Work Element Precedence Time (Min)
A Press out sheet of
fruits
----- 0.1
B Cut into strips A 0.2
C Outline Fun Shapes A 0.4
D Roll up and package B,C 0.3
Total 1.0
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

13. Precedence Diagram
Precedence diagram: Tool used in line
balancing to display elemental tasks and
sequence requirements
A Simple Precedence
Diagram
A
B
C
D
0.1 min. 0.2 min.
0.4 min.
0.3 min.
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

14. Calculate the desired CT (Takt
Time)
TT = 40 h * 60 m/ h = 2400
6000 units 6000
= 0.4 minute
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

15. Calculate the theoretical minimum
number of workstations
N = 0.1 + 0.2 + 0.3 + 0.4 = 1.0 = 2.5
0.4 0.4
N= 2.5 = 3 workstations
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

16. Assembly Line Balancing
 Arrange tasks shown in the previous
slide into workstations.
◦ Use a cycle time of 0.4 minute
◦ Assign tasks in order of the most number of
followers
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

17. Work
Station
Work
Element
Remaining
time
Remaining
Elements
1 A 0.3 B C
B 0.1 C D
2 C 00 D
3 D 0.1 None
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

18. A
B
C
D
0.1 min.
0.2 min.
0.4 min.
0.3 min.
Assembly line with three workstations
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

19. A B C D
Workstation -01 Workstation -02 Workstation -03
0.3 m 0.4 m 0.3 m
Assembly Line
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

20. Calculate Percent Idle Time
Percent idle time =
Idle time per cycle
(N)(CT)
PIT = 0.2/ 3 (0.4) = 16.6 %
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

21. Determine the Efficiency
stask timeofsum=t
actual)(CTn
t)(
=E


E = 0.1 +0.2+0.3+0.4 = 1.0/ 1.2 = 83.3%
3 (0.4)
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

22. Requirements:
◦ List of departments
◦ Projection of work flows
◦ Distance between locations
◦ Amount of money to be invested
◦ List of special considerations
Designing Process Layouts
6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)

23. 6/28/2015 DMAKulasooriya, NIBM (UCD -BSc-2011)