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GOM3OperationsManagement

Layout1GOM314BasicProductionLayoutsProcessLayoutProductLayoutGroupTechnology(Cellular)LayoutFixed-PositionLayout24BasicProductionLayoutsProceLayoutTypesFoundryMillingmachinesLathesGrindingPaintingDrillsOfficeWeldingForging(a)Layoutofajobshop3LayoutTypesFoundryMillingmacProcessLayoutAdvantages:generalpurposeandlesscapitalintensivelessvulnerabletochangesequipmentutilizationemployeesupervisionDisadvantages:slowerprocessingrateslostproductiontimeforsetupsmorecapitalandspaceforinventorylongermanufacturingleadtimesmaterialshandlingrequiresvariablepathdevicesproductionplanningandcontrolmoredifficult4ProcessLayoutAdvantages:4LayoutTypesStation1Station2Station3Station4(b)Layoutofaproductionline5LayoutTypesStation1Station2ProductLayoutAdvantages:fasterprocessingrateslowerinventoriesinfrequentsetupsDisadvantages:riskoflayoutredesignlessflexibilityforlowvolume,dedicatedresourceshavelowutilization6ProductLayoutAdvantages:6GroupTechnology(a)JumbledflowsinajobshopwithoutGTcellsDrillingDDDDGrindingGGGGGGMillingMMMMMMAssemblyAAAALathingReceivingandshippingLLLLLLLL7GroupTechnology(a)JumbledflGroupTechnology(b)LineflowsinajobshopwiththreeGTcellsCell3LMGGCell1Cell2AssemblyareaAALMDLLMShippingDReceivingG8GroupTechnology(b)LineflowsGroupTechnology(b)LineflowsinajobshopwiththreeGTcellsCell3LMGGCell1Cell2AssemblyareaAALMDLLMShippingDReceivingG9GroupTechnology(b)Lineflows34GroupTechnology

Benefits1.Betterhumanrelations2.Improvedoperatorexpertise3.Lessin-processinventoryandmaterialhandling4.Fasterproductionsetup1034GroupTechnology

Benefits1.35GroupTechnology

TransitionfromProcessLayout1.Groupingpartsintofamiliesthatfollowacommonsequenceofsteps.2.Identifyingdominantflowpatternsofpartsfamiliesasabasisforlocationorrelocationofprocesses.3.Physicallygroupingmachinesandprocessesintocells.1135GroupTechnology

TransitionExample:ProcessFlowAnalysisAssumethatKingSportsProductsproducesavarietyoftennisracketssequentiallyonfourmachines,andthetimesrequiredoneachmachineforonetypicalracketareshownasfollows:RawMaterialsMachineAFramer4minutesMachineBHandler3minutesMachineCStringer10minutesMachineDFinisher2minutesRacket12Example:ProcessFlowAnalysisExample:ProcessFlowAnalysisThroughputtime:4+3+10+2=19minutesCycletimeoftheprocess:10minutesIfKingiswillingtoinvestinanothermachine,whichtypeshoulditpurchase?Howmuchmorecanyouimproveifyouhavemoreresources?13Example:ProcessFlowAnalysisExample:ProcessFlowAnalysisRawmaterials2-toncapacity1load/dayTruckAParts300cap.1.5Tons/day240Parts/dayStorage3500lb.cap.Storage500cap.Fabrication25lb/component25component/hrAssembly20units/hrPackagingA5cesstime30Parts/hr375Lb/hr15Components/hr15Units/hr120Units/day80Units/dayPackagingB10cesstime40Units/dayTruckBThebottleneckshiftsaroundthefacilityHow?14Example:ProcessFlowAnalysis16Example--LineBalancingYou’vejustbeenassignedthejobofsettingupanelectricfanassemblylinewiththefollowingtasks:1516Example--LineBalancingYou’v17PrecedenceDiagramACBDEFGH23.2511.2.511.41Whichprocessstepdefinesthemaximumrateofproduction?1617PrecedenceDiagramACBDEFGH2318Thebottleneck1718Thebottleneck1719Wewanttoassembly100fansperdayWhatdoesthisfigurerepresent?1819Wewanttoassembly100fansWhyshouldwealwaysroundup?20TheMcGraw-HillCompanies,Inc.,1998Irwin/McGraw-Hill19Whyshouldwealwaysroundup?21SomeRulesWe’llFollowforLoadingWorkstationsPrimary:Assigntasksinorderofthelargestnumberoffollowingtasks.Secondary(tie-breaking):Assigntasksinorderofthelongestoperatingtime2021SomeRulesWe’llFollowforACBDEFGH23.2511.2.511.41Station1Station2Station3TaskFollowersTime(Mins)A62C43.25D31.2B21E20.5F11G11H01.423TheMcGraw-HillCompanies,Inc.,1998Irwin/McGraw-Hill21ACBDEFGH23.2511.2.511.41Statio33EfficiencyoftheAssemblyLine2233EfficiencyoftheAssemblyLGOM3OperationsManagement

Layout23GOM314BasicProductionLayoutsProcessLayoutProductLayoutGroupTechnology(Cellular)LayoutFixed-PositionLayout244BasicProductionLayoutsProceLayoutTypesFoundryMillingmachinesLathesGrindingPaintingDrillsOfficeWeldingForging(a)Layoutofajobshop25LayoutTypesFoundryMillingmacProcessLayoutAdvantages:generalpurposeandlesscapitalintensivelessvulnerabletochangesequipmentutilizationemployeesupervisionDisadvantages:slowerprocessingrateslostproductiontimeforsetupsmorecapitalandspaceforinventorylongermanufacturingleadtimesmaterialshandlingrequiresvariablepathdevicesproductionplanningandcontrolmoredifficult26ProcessLayoutAdvantages:4LayoutTypesStation1Station2Station3Station4(b)Layoutofaproductionline27LayoutTypesStation1Station2ProductLayoutAdvantages:fasterprocessingrateslowerinventoriesinfrequentsetupsDisadvantages:riskoflayoutredesignlessflexibilityforlowvolume,dedicatedresourceshavelowutilization28ProductLayoutAdvantages:6GroupTechnology(a)JumbledflowsinajobshopwithoutGTcellsDrillingDDDDGrindingGGGGGGMillingMMMMMMAssemblyAAAALathingReceivingandshippingLLLLLLLL29GroupTechnology(a)JumbledflGroupTechnology(b)LineflowsinajobshopwiththreeGTcellsCell3LMGGCell1Cell2AssemblyareaAALMDLLMShippingDReceivingG30GroupTechnology(b)LineflowsGroupTechnology(b)LineflowsinajobshopwiththreeGTcellsCell3LMGGCell1Cell2AssemblyareaAALMDLLMShippingDReceivingG31GroupTechnology(b)Lineflows34GroupTechnology

Benefits1.Betterhumanrelations2.Improvedoperatorexpertise3.Lessin-processinventoryandmaterialhandling4.Fasterproductionsetup3234GroupTechnology

Benefits1.35GroupTechnology

TransitionfromProcessLayout1.Groupingpartsintofamiliesthatfollowacommonsequenceofsteps.2.Identifyingdominantflowpatternsofpartsfamiliesasabasisforlocationorrelocationofprocesses.3.Physicallygroupingmachinesandprocessesintocells.3335GroupTechnology

TransitionExample:ProcessFlowAnalysisAssumethatKingSportsProductsproducesavarietyoftennisracketssequentiallyonfourmachines,andthetimesrequiredoneachmachineforonetypicalracketareshownasfollows:RawMaterialsMachineAFramer4minutesMachineBHandler3minutesMachineCStringer10minutesMachineDFinisher2minutesRacket34Example:ProcessFlowAnalysisExample:ProcessFlowAnalysisThroughputtime:4+3+10+2=19minutesCycletimeoftheprocess:10minutesIfKingiswillingtoinvestinanothermachine,whichtypeshoulditpurchase?Howmuchmorecanyouimproveifyouhavemoreresources?35Example:ProcessFlowAnalysisExample:ProcessFlowAnalysisRawmaterials2-toncapacity1load/dayTruckAParts300cap.1.5Tons/day240Parts/dayStorage3500lb.cap.Storage500cap.Fabrication25lb/component25component/hrAssembly20units/hrPackagingA5cesstime30Parts/hr375Lb/hr15Components/hr15Units/hr120Units/day80Units/dayPackagingB10cesstime40Units/dayTruckBThebottleneckshiftsaroundthefacilityHow?36Example:ProcessFlowAnalysis16Example--LineBalancingYou’vejustbeenassignedthejobofsettingupanelectricfanassemblylinewiththefollowingtasks:3716Example--LineBalancingYou’v17PrecedenceDiagramACBDEFGH23.2511.2.511.41Whichprocessstepde

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