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Process and Material Flow Analysis
Published in Sunderesh S. Heragu, Facilities Design, 2022
Machines and workstations in a process layout are arranged based on the operations they perform. Thus, all milling machines are placed together in one department, all turning machines are placed together in another, and so on. In Figure 7.7, a typical process layout is shown with all the lathes (indicated as L) are in the leftmost department, and all the milling, drilling, grinding, painting, and assembly machines (identified as M, D, G, P, and A, respectively) are in their respective departments. Other names for process layout include layout by process and job-shop layout. The process layout is useful for companies that manufacture a variety of products or jobs in small quantities, where each job is usually different from any other. While the process layout offers flexibility and allows personnel to become experts in a particular process or function, it has some major disadvantages—increased material handling costs, traffic congestion, long product cycle times and queues, complexity in planning and control, and decreased productivity.
The Location and Layout Plan
Published in David C. Kimball, Robert N. Lussier, Entrepreneurship Skills for New Ventures, 2020
David C. Kimball, Robert N. Lussier
Having committed to a building, you must develop a layout, the arrangement of the physical facilities in the most efficient manner for the specific business, for the interior in order to maximize profitability. The differences in layout of the retail, wholesale, service, and manufacturing firms depend upon the demand of customers or clients. A manufacturing firm wants to minimize production costs, while a retail store wants to ensure that customers, upon entering the facility, have the opportunity to select high-profit impulse items. A manufacturing firm might utilize a product layout, which refers to the arrangement of the machinery and personnel in the sequential order of the manufacturing process, or a process layout, where machinery is grouped according to machine function. A retail store, which makes a low profit on demand items, specific items that a customer needs to purchase, wants to assure that these are accessible only after the customer passes by the high-profit impulse items. A wholesale firm’s layout is dependent upon minimizing the cost of filling the derived demand order of the retailers. The location of service companies depends upon whether the customer goes to the location for service or the service people go to the customer. In the former case, service firms have to consider most of the location considerations affecting the retail store. In the latter case, it might not matter where the source company had its location, except that it should be located where cost is at a minimum.
The Lean / Just-in-Time Concept and Repetitive Manufacturing
Published in Paul Schönsleben, Integral Logistics Management, 2018
Segmentation can lead to goods-flow-oriented areas and allow autonomous responsibility for products to arise (similar to line production when organizational boundaries interrupting flow are eliminated). Figure 6.2.2.1 shows: In the upper section, an example of a process layout: Operations of a similar nature or function are grouped together, based on process specialty (for example, saw, lathe, mill).In the lower section, an example of a product layout: For each product (here with the exception of painting and galvanizing) there is a separate production line, or manufacturing group, but no longer any central job shop for each task.
Cellular manufacturing design 1996–2021: a review and introduction to applications of Industry 4.0
Published in International Journal of Production Research, 2023
Roohollah YounesSinaki, Azadeh Sadeghi, Hadi Mosadegh, Najat Almasarwah, Gursel Suer
As a mid-term planning problem, cell planning focuses on tactical decisions such as capacity planning, process selection, labour allocation and inventory decisions. Also, due to demand fluctuations, managers may make some slight modifications to their strategical decisions including facility layout which is based on the adoption of appropriate production system with respect to production volumes and product variety. According to Tompkins et al. (2003), U.S. manufacturing firms invest around $250 billion annual budget for designing, planning, and re-planning of their manufacturing plants and layouts. Considering the plant layout characteristics, manufacturing systems are divided into four main categories: cellular layout, product layout, process layout, and fixed-position layout (for further discussion, see Hosseini-Nasab et al. 2018).
Efficient Fab facility layout with spine structure using genetic algorithm under various material-handling considerations
Published in International Journal of Production Research, 2022
Second, the methodology of this study can suggest various ideas for dispersing material flows and minimising the traffic congestions. Generally, in order to determine the arrangement of layout in which the overall distance of congested material handling between processes is minimised, it is common to place the processes close to each other, considering the closeness between processes (Yang, Su, and Hsu 2000). However, in the spine structure, if the related two processes are arranged with the central corridor between them or with the flow of process opposite to the running direction of OHT, such a process layout might cause traffic congestion in the central corridor and even worsen the overall efficiency of material handling. Therefore, the layout methodology proposed in this study can contribute to determining the layout that can decrease the risk of traffic congestion caused by AMHS in Fab with a spine structure.
Consideration of processing time dissimilarity in batch-cyclic scheduling of flowshop cells
Published in International Journal of Production Research, 2021
Najat Almasarwah, Gürsel A. Süer
Manufacturing systems are divided into four types of layouts as Product Layout, Process Layout, Cellular Layout, and Fixed Layout based on production volume and product variety. Figure 1 presents the types of manufacturing system layouts. Dissimilar machines are brought together into a production line in the product layout, and each production line meets the high-volume demand -for a product. In the process layout, similar machines are grouped into different departments. The products move from one department to another before the final product is completed. In the cellular layout, similar products are grouped into a product family based on their processing similarity where each cell has dissimilar machines required to run the product family. In a fixed layout, the product remains in a fixed position, and machines and workers move around the product (Askin and Standridge 1993; Süer, Huang, and Maddisetty 2010).