Chapter 3
Line balancing -
A technique used in developing product-based layouts that works by assigning tasks to a series of linked workstations in a manner that minimizes the number of workstations and minimizes the total amount of idle time at all stations for a given output level.
Product-based layout:
A type of layout where resources are arranged sequentially, according to the steps required to make a product.
Functional layout:
A type of layout where resources are physically grouped by function.
Fixed-Position Layout -
A type of manufacturing process in which the position of the product is fixed. -Materials, equipment, and workers are transported to and from the product. -Used in industries where the products are very bulky, massive, or heavy and movement is problematic. -Examples include shipbuilding, construction projects, and traditional home building.
Continuous Flow Processes -
A type of manufacturing process that produces highly standardized products using a tightly linked, paced sequence of steps. -Closely resembles the production line process -Form of product usually cannot be broken into discrete units. -Examples include yarns and fabric, food products, and chemical products such as oil and gas
Job Shops -
A type of manufacturing process used to make a wide variety of highly customized products in quantities as small as one. -Characterized by general-purpose equipment and broadly skilled workers. -Main emphasis is meeting a customer's unique requirements. -Product design is not standardized. -Typically follow a functional layout. -Examples include custom furniture, specialized machine tools used by manufacturers, and restoration and refurbishing work.
Cellular layout -
Production resources are dedicated to a subset of products with similar requirements known as a product family.
Fixed position layout -
Productive resources have to be moved to where the product is being made or the service is being provided.
Name 5 Manufacturer Processes:
-Continuous Flow -Production Line -Batch Manufacturing -Job Shop -Fixed Position Layout
Layout Decision Model:
-Fixed position layout -Product-based layout -Functional layout -Cellular layout
Production Line -
A type of manufacturing process used to produce a narrow range of standard items with identical or highly similar designs. -Follows a product-based layout -Steps are usually linked by some system that moves the items from one step to the next. -Suitable for high-volume production of product(s) characterized by similar design attributes. -Need high volumes to justify the required investment in specialized equipment and labor. -Are inflexible with regard to items that do not fit the design characteristics of the production line.
Batch Manufacturing -
A type of manufacturing process where items are moved through the different manufacturing steps in groups or batches. -Fits between job shops and lines in terms of production volumes and flexibility and strikes a balance between the flexibility of a job shop and the efficiency of a line. -Are the most common type of manufacturing process. -The sequence of steps is not as tightly linked as a production line. -Flexible Manufacturing Systems - Highly automated batch processes that can reduce the cost of making groups of similar products.
Product-based layout -
Arranges resources sequentially, according to the steps required to make a product or provide a service.
Four Levels of Customization:
Engineer-to-order (ETO) - Products are designed and produced from the start to meet unusual customer needs or requirements. Make-to-order (MTO) - Products that use standard components but the final configuration of those components is customer specific. Assemble-to-order (ATO) - Products that are customized only at the very end of the manufacturing process. Make-to-stock (MTS) - Products that require no customization.
Functional layout -
Physically groups resources by function.
Takt Time Formula:
Takt Time = Available production time / Required output rate.