Departmental Planning and Production Layouts

Oct 3, 2024

Lecture Two Part One Continuation Notes

Departmental Planning

  • Involves various areas: production, support, administrative, and service.
  • Production planning departments consist of workstations grouped during facilities layout process.
  • Classification of production planning departments:
    1. Product Fixed
    2. Product Family (Group Technology)
    3. Process Planning

Factors for Choosing Production Planning Strategies

  • Based on volume (how many products produced) and variety (types of products).
    • High Volume / Low Variety: Product Layout
    • Low Volume / High Variety: Process Layout
    • Low Volume / Low Variety: Fixed Location Layout (e.g., airplane manufacturing)
    • Medium Volume / Medium Variety: Product Family Layout

Procedural Guide for Combining Workstations

  1. Standardized Product with Stable Demand: Use Production Line/Product Department.
    • Combine all workstations for that product.
  2. Physically Large Product with Low Demand: Use Fixed Materials Location/Product Department.
    • Combine workstations in the staging area.
  3. Grouped Families of Similar Parts: Use Product Family/Product Department.
    • Combine workstations for that family of products.
  4. No Classifications: Use Process Department.
    • Combine identical workstations into initial planning departments.

Product Family Departments (PFD)

  • Aggregate parts into families with similar manufacturing operations/design attributes.
  • Cells formed through clustering of machines required for the part family.

Direct Clustering Algorithm (DCA) Methodology

Steps:

  1. Order Rows and Columns
    • Sum the number of parts processed by each machine.
    • Sort rows in descending order of totals, columns in ascending order.
  2. Sort Columns
    • Shift columns left based on processing for the top row.
  3. Sort Rows
    • Move rows upward based on the first column.
  4. Form Cells
    • Identify opportunities to group machines for parts.

Example Application of DCA

  • Machines and parts matrix created.
  • Steps demonstrated: Summing, ordering, sorting, and forming cells.
  • Resulted in two cells for parts based on machine requirements.

Layout Types Based on Material Flow Systems

  • Types of Production Planning Departments:
    1. Production Line Departments
    2. Fixed Material Location Departments
    3. Product Family Departments
    4. Process Departments

Advantages and Disadvantages of Layouts

  • Production Line/Product Layout:

    • Advantages:
      • Smooth flow, reduced inventory, short production time, less skill required, simple production control.
    • Disadvantages:
      • Machine breakdown halts production, layout changes needed for new products, higher investment required.
  • Fixed Product Layout (e.g., airplanes):

    • Advantages:
      • Continuity, job enrichment, highly flexible, accommodates design changes.
    • Disadvantages:
      • Increased equipment movement, requires greater skill, more space required.
  • Product Family Layout:

    • Advantages:
      • Higher machine utilization, smoother flow, benefits of team atmosphere.
    • Disadvantages:
      • General supervision required, higher skill levels needed, unbalanced flow can cause issues.
  • Process Layout:

    • Advantages:
      • Increased machine utilization, flexibility, diversity of tasks.
    • Disadvantages:
      • Complicated production control, increased material handling, higher skill required.

Conclusion

  • Discussed departmental planning, layout types, and material flow systems.
  • Understanding advantages and limitations of each layout is crucial for effective planning.