B A S I C P RO D U C T I O N L AYO U T F O R M AT S The formats by which departments are arranged in a facility are defined by the general pattern of...
Catalytic reforming is a chemical process used to convert petroleum naphtha into high – octane gasoline called reformate. In addition, catalytic reforming is a primary process of aromatics (…Full description
PIDDescrição completa
Deskripsi lengkap
asdfafFull description
Full description
Food companies today are like other manufacturing businesses not only focusing on the reliability and quality of the food processing equipment but also on various services which the suppl…Full description
3b) Suggest two Layouts that Dell can adopt for production. Give reasons for your answer. answer. B A S I C P RO D U C T I O N L AYO U T F O R M AT S
The formats by which departments departments are arranged arranged in a facility are dened by the general pattern of wor !ow" there are three basic types #process layout$ product layout$ and %ed&position layout) and one hybrid type #group technology or cellular layout). The first decision is to determine the type of manufacturing operation that Dell Computers want to accommodate. This depends on product olume and ariety. !t one e"treme# the factory will produce a wide ariety of $espo%e products in small olumes# each of which is different &this is called a '(o$$ing) operation*. operation*. !t the other e"treme it will produce a continuous stream of identical products in large olumes. +etween the e"tremes# the factory might produce arious si,ed $atches of a range of different products. BASIC LAYOUT TYPES nce the type of operation has $een selected &(o$$ing# $atch or continuous* the $asic layout type needs needs to $e selected. selected. There are three three $asic types
•
Process layout Cell layout
•
Product layout
•
/o$$ing operations &high ariety0low olume* olume* tend to adopt a process layout. +atch operations &medium ariety and olume* adopt either a cell or process layout. Continuous operations &low ariety0high olume* adopt a product layout.
1. Proc Proces ess s layo layout ut
1n process layout# similar manufacturing processes &cutting# drilling# wiring# etc.* are located together to improe improe utilisation. Different products products may re2uire different different processes so material flow patterns can $e comple". !n e"ample is machining machining parts parts for computers and aircraft aircraft engines. engines. 3ome processes processes &such as heat treatment* t reatment* need specialist support &e.g. fume e"traction*# while other processes &e.g. machining centers* need t echnical support from machine setters0operators. setters0operators. 3o the factory will $e arranged arranged with heat treatment together together in one location and machining centers in another. Different products will follow different routes around the factory.
Page 4 of 5
UK-RF Closed Nuclear Cities Partnership
2. Cell layout
1n cell layout# the materials and information entering the operation are pre-selected to moe to one part of the operation &or cell* in which all the machines to process these resources are located. !fter $eing processed in the cell# the part-finished products may go on to another cell. 1n effect the cell layout $rings some order to the comple"ity of flow that characterises process layout. !n e"ample is specialist computer component manufacture. The processing and assem$ly of some types of computer components may need a dedicated cell for manufacturing parts to the 2uality re2uirements of a particular customer.
3. Product layout
Product layout inoles locating the machines and e2uipment so that each product follows a pre-arranged route through a series of processes. The products flow along a line of processes# which is clear# predicta$le and relatiely easy to control. !n e"ample is computer assem$ly# where almost all ariants of the same model re2uire the same se2uence of processes.
SELECTING A LAYOUT TYPE
Ta$le 4 shows some of the more significant adantages and disadantages of each layout type. ne significant difference is their association with fixed and variable costs. Process layouts tend to hae relatiely low fi"ed costs $ut high aria$le costs# as each product is different. +y contrast# product layouts hae high fi"ed costs to set up the manufacturing lines# then low aria$le costs for producing large olumes of the same product. 6ence if olume is high and aria$ility low# product layout is li%ely to $e the $est option.
Ta$le 4 !dantages and disadantages of different layout types
7ayout
!dantages
Disadantages
Proces s
6igh mi" and product fle"i$ility
7ow utilisation of machines
Ro$ust against disruptions
Can hae high wor%-in-progress
8asy to superise e2uipment
Comple" flow can $e difficult to control
9ood compromise $etween cost and fle"i$ility for highariety operations
:ore machines needed
Cell
Page ; of 5
Can gie lower plant utilisation
UK-RF Closed Nuclear Cities Partnership
Fast throughput Product
7ow unit costs for high olume
7ow fle"i$ility
82uipment can $e specialised# improing efficiency
Not ery ro$ust to disruptions
:aterials moement optimised
Detailed design in PROCESS layout
The detailed design of process layouts is comple"# $ecause of the comple" wor%flow patterns that are associated with this layout to ensure a ery wide ariety of products can $e made. ptimal solutions are difficult to achiee and most process layouts are designed through intuition# common sense and systematic trial and error.
To design a process layout# the designer needs to %now •
The area re2uired $y each wor% centre.
•
The constraints on the shape of the area allocated for each wor% centre.
•
The degree and direction of flow $etween each wor% centre &for e"ample num$er of (ourneys# num$er of loads# cost of flow per distance traelled*. The desira$ility of wor% centres $eing close together.
•
The degree and direction of flow are usually shown on a flow record chart# li%e that in Figure 4&a*# which records in this case the num$er of loads per day transported $etween wor% centres. 1f the direction of flow $etween wor% centres ma%es little difference to the layout# then the information can $e collapsed as shown in Figure 1n some operations# the cost of moing materials $etween different wor% centres aries considera$ly. For e"ample in Figure 4&c* the unit cost of moing a load $etween the fie wor% centres is shown. The unit cost of moing loads from wor% centre + is slightly higher than from most other centres# perhaps $ecause products need careful handling $etween these operations. Com$ining the unit cost and flow data gies the cost per distance traelled data shown in Figure 4&d*. :inimising the distance $etween + and C and $etween + and 8 would reduce the oerall costs of production with this process layout.
'f direction is not important$ collapses to &a* 7oads0day
From0T o
!
&$* 7oads0day
+
C
D
8
Page < of 5
UK-RF Closed Nuclear Cities Partnership
!
4 =
-
< >
4 >
; >
-
; >
-
= >
+
4 <
C
-
4 >
D
< >
-
8
4 >
4 Fr 4 > om > 0To
-
< > ! 4
+
C
D
8
>
! centres$ combine <> 5> 'f cost of !ow di(ers between wor with +
<>
C
-
<>
-
@>
D
?>
8 &c* Unit traelled
From0 To
;>
To give cost0distance &d* Daily cost0distance traelled
Figure 4 Collecting information in process layout
The general approach to determining the location of wor% centres in a process layout is as follows
4. Collect information relating to the wor% centres and flow $etween them. ;. Draw up a schematic layout showing the wor% centres and the flow $etween them# putting the wor% centres with the greatest flow closest to each other. <. !d(ust the schematic layout to ta%e into account the constraints of the area into which the layout must fit. ?. Draw the layout showing the actual wor% centre areas and distances that materials must trael. Calculate the effectieness measure of the layout either as total distance traelled or as the cost of moement.
