Layouts

Manufacturing Layouts Overview

• Presentation by Paul Fidler on January 23, 2023

Agenda

• Manufacturing Layouts: Brief explanation

• Application of Layouts: When each layout is used and reasons behind them

• Hands-on Exercise: Using two different layouts

• Discussion: Group conversation on layouts

Layout Choices

• Intermittent Layouts

  • Lot or batch processing

• Flow Layouts

  • Repetitive, also known as line or cell layouts

  • Continuous layouts (not covered)

• Project Layouts

  • Fixed position layout (brief mention only)

Process Layout

• Organization: Arranged by grouping similar equipment

  • Ideal for batch processing, not fluid

  • Avoids silo mentality with physical separation of processes

  • Creates Work-in-Progress (WIP) inventory

• Characteristics:

  • Also known as intermittent, functional, or job shop layout

  • Requires specialized knowledge and setup operators

  • Equipment grouped by function, similar skills in departments

  • Not high volume to justify assembly line efficiency

Intermittent (Job Shop) Layout

• Workstations Arrangement: Items of different products are distributed across various workstations (A, B, C)

• Characteristics:

  • Jumbled pattern of product designs moving through workstations

  • Not all stations used for every part

  • Standard (non-custom) machinery

  • Flexibility in changing product types or volumes

  • Complex, expensive production and inventory management

  • High WIP inventory levels and long lead times

Flow Layouts

• Sequencing: Workstations sequenced to match the required product assembly

  • Limited range of products produced

  • Line balancing essential to maintain constant flow

  • Minimum WIP maintained to avoid delays

  • Potentially high capital costs due to custom equipment requirements

Cellular Layout

• Definition: A flow production method enabling one-piece flow with minimal WIP inventory

  • Compact setup leads to better communication and teamwork

  • Can function with one or multiple operators

Benefits of Cellular Layout

• Production Efficiency:

  • Reduced queues and floor space

  • Simplified activity control and material movement

  • Immediate feedback on production processes

• Outcomes:

  • Greater production flexibility

  • Smaller lot sizes, improved product quality

Advantages of Flow (Product) Layout

• Efficiency Gains:

  • Shortened lead times

  • Reduced job sizes or Kanban levels

  • Lower cost per piece produced

  • Dramatically reduced WIP and fewer rejects of finished goods

One Piece Flow vs. Batch Manufacture

• Issues in Batch Manufacturing:

  • Often leads to inhibited material flow and accumulation of WIP

• Advantages of One Piece Flow:

  • Eliminates inventory delays between processes, enhancing speed

  • Reduced lead times from 7 hours in batch to 3 hours in one piece flow

Class Problem Discussion Topics

• Evaluate if product volume is higher than processing capacity (T/F)

  • Consider factors like inventory control costs, WIP, lead time, run costs, annual setup costs, and capital costs

Practical Exercise: Making Something!

• Engage in a practical activity with instructions for creating an airplane

  • Online resources provided for guidance: www.10PaperAirplanes.com