2. Manufacturing System Design & Control
Facility Layout and Work Flow
Arrangement within a factory of:
•Machines
•Departments
•Workstations
•Storage areas
•Aisles and common areas
Ensures a smooth flow of work, material, people and
information through the system
3. Manufacturing System Design & Control
3 three basic types of layout:
•Process
•Product
•Fixed-Position
3 hybrid layouts:
•Cellular
•Flexible Manufacturing Systems
•Mixed-model Assembly Lines
4. Manufacturing System Design Control
Process Layout:
•Similar activities grouped together in work areas
•Suitable for low volume or batch production
•Flexible
•Not very efficient
•Storage space – large receiving, small shipping
•Large aisles for movement of material
Lathe
Department
Milling Department Drilling Department
Grinding Department Painting Department
Receiving and Shipping
Assembly
L L
L L
L
L
L
L
M M M
G G G G
D D D D
D D D D
P
P
A A A
5. Manufacturing System Design Control
Product Layout:
•Arrange activities in sequence of operation
•Line set up for one product
•Specialised machines
•Suitable for mass production
•More automated than process layouts
•Efficient
•Line flow – avoid bottlenecks
•Not flexible
IN
OUT
6. Manufacturing System Design Control
Fixed Position Layout:
•Large projects too big to move
•Equipment and parts moved in and out of work area
•Highly skilled workers - costly
7. Manufacturing System Design Control
Hybrid Layouts:
Try to mix flexibility of process layout with efficiency of
product layout
Cellular Layouts:
•Machines grouped into cells
•Cells process parts with similar features
•Work cell resembles a small assembly line (product)
•Layout between cells treated as process layout
10. Manufacturing System Design Control
Flexible Manufacturing Systems:
•Automates the entire manufacture of a
product
•Very costly
•Complex software
•Small number of FMS worldwide
Flexible Manufacturing Cell:
•Smaller version of FMS
•One manufacturing process is automated
11. Manufacturing System Design Control
Progressive FMS:
•All parts follow same progression through the work
stations
•Best where group technology can be applied
Progressive FMS
Load Station
Unload Station
Pallet
12. Manufacturing System Design Control
Closed Loop FMS:
•Larger variety of parts
•Parts can follow different paths
•Parts can skip stations
Closed Loop FMS
Pallet
Unload
Load
13. Manufacturing System Design Control
Ladder FMS layout:
•Parts moved to and from any machine in any
sequence
•More flexible than progressive and closed loop
systems Load/Unload
14. Manufacturing System Design Control
Mixed Model Assembly Lines:
•More than one product is processed by the line
•Workers trained to work on more than one station
•Layout of line changed
•Long and short operations arranged to cancel
each other
Traditional line
U Shaped Line
15. Capacity Management:
•Demand for product can fluctuate over time
•Capacity < demand - Lose business
•Excess capacity: storage cost, labour cost etc.
•Capacity planning: match capacity to present and
anticipated demand
Capacity Planning
•Capacity Lead Strategy
•Capacity Lag Strategy
•Average Capacity Strategy
Manufacturing System Design Control
16. Manufacturing System Design Control
Capacity Lead Strategy
•Capacity expanded in anticipation of demand
•Expect to gain customers from competitors
Demand
Capacity
Quantity
Time
17. Manufacturing System Design Control
Capacity Lag Strategy
•Capacity increased after increased in demand
•Common where competition is weak
Demand
Capacity
Time
Quantity
18. Manufacturing System Design Control
Average Strategy Lag
•Capacity expanded to coincide with average
expected demand
Demand
Capacity
Quantity
Time
19. Manufacturing System Design Control
How much to increase capacity?
•100% capacity not efficient
•20% cushion is generally used
•20% capacity allows for unexpected demand
•Negative capacity can be used - Airlines
