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1 Process Selection and Facility Layout
Process Selection and Facility Layout
2 Process Selection and Facility Layout
Introduction
• Process selection– Deciding on the way production of goods or
services will be organized
• Major implications– Capacity planning– Layout of facilities– Equipment– Design of work systems
3 Process Selection and Facility Layout
Forecasting
Product andService Design
TechnologicalChange
CapacityPlanning
ProcessSelection
Facilities andEquipment
Layout
WorkDesign
Process Selection and System Design
4 Process Selection and Facility Layout
Process Selection
• Variety– How much
• Flexibility– What degree
• Volume – Expected output
Job Shop
Batch
Repetitive
Continuous
ProjectProcess Types
5 Process Selection and Facility Layout
Process Types
• Projects– Unique
• Job shop– Small scale
• Batch– Moderate volume in lots
• Repetitive/assembly line– High volumes of standardized goods or
services• Continuous
– Very high volumes, Highly standardize
6 Process Selection and Facility Layout
Product – Process Matrix
Oil refineryGenerating
Electricity
Notfeasible
Continuous(flow)
Automotiveassembly
Automaticcarwash
Repetitive
Commercialbakery
ClassroomLecture
Batch
Not feasible
Appliance repair
Emergency room
Job Shop
Process Type
Project BridgesHighways
VolumeF
lex
ibili
ty /
Mix
NotFeasible
NotFeasible
7 Process Selection and Facility Layout
Project Non-Routine, Often “One Of A Kind” OperationLimited Time Frame To Complete
Steps Involved in Project Process 1.Project initiation stage;2.Project planning or design stage;3.Project execution or production stage;4.Project monitoring and controlling systems;5.Project completion stage.
Manufacturing : Buildings, Dams, Bridges, Ships
Service : Crisis Management (Hurricane Recovery)
8 Process Selection and Facility Layout
Job Shops
Low Volume – High Variety of Goods& Services
Processes may change from job to job.
Highly flexible workforce and equipment.
Manufacturing Examples: Tool & Die Shop,Custom Car Painting
Service Examples: Beauty Solon, Hospital,Veterinarians Office(Many animals, many issues)
9 Process Selection and Facility Layout
Batch ProcessesMedium Volume having job shop flexibility
using repetitive techniques.
Easy to set-up processes.
Process runs batches using repetitive techniques. Flexible Automation
Manufacturing Examples: Small Bakery,PIP style printing
Service Examples: TV Show Production, Airline baggage handling
10 Process Selection and Facility Layout
Repetitive / Assembly Line
High Volume – Low Variety of Goods & Services
Processes are very constant with little change.
Lower skilled workers needed – Fixed Automation
Manufacturing Examples: Auto Assembly, High Volume Electronics
Service Examples – Cafeteria Lines, Ticket Takers
11 Process Selection and Facility Layout
Continuous ProcessesVery High Volume – Very Low Variety
Continuous Processes
Frequently totally automatedFixed (hard) automation
Manufacturing Examples: Making Steel, Fiberglass, Petrochemicals, Generating Electricity.
Service Examples: Internet, Air Quality Monitoring, Delivering Electricity
12 Process Selection and Facility Layout
Automation
• “Machinery or equipment with sensing devices that enable it to operate."
– ATM’s To Robots
Commonly used term with many meanings.
Fixed Automation / Hard AutomationProgrammable Automation
13 Process Selection and Facility Layout
Fixed vs. Programmable Automation
Fixed Automation – designed to do a specific task.Specialized equipment – high volume at low cost,inflexible.
Programmable Automation – may be reprogrammed to do many different tasks.General purpose equipment – lower volume/ higher variety, very flexible.
14 Process Selection and Facility Layout
Automation
Reduce Human variation Improve Quality – consistency Safety Productivity?? Others
Advantages of Automation?
15 Process Selection and Facility Layout
Automation
– Costs!– Lack of flexibility - Limitations
• People can think, feel, make decisions
– Support personnel needed– Must use to be cost effective– Other
Disadvantages of Automation?
