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Questions and Answers
What is the primary benefit of using three-dimensional visualization software in facility layout planning?
What is a characteristic of a focused factory?
What is a key requirement for the success of a work cell?
What is a potential benefit of implementing work cells?
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What is a key aspect of employee empowerment in a work cell?
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What is the main characteristic of a focused work center?
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What is the main purpose of a fabrication line?
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What is necessary to balance a fabrication line?
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What is the primary characteristic of a focused factory?
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What is a common requirement for both fabrication lines and assembly lines?
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What is the primary objective of warehouse and storage layouts?
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What is the effect of increasing the number of different items stored on warehouse density?
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What is the primary characteristic of cross-docking?
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What is the benefit of using automated storage and retrieval systems (ASRSs)?
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What is the primary purpose of random stocking?
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What is the primary objective of maximizing warehouse 'cube'?
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What is the primary benefit of using Automated Storage and Retrieval Systems (ASRSs)?
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What is the key requirement for the success of cross-docking operations?
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What is the primary purpose of random stocking?
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What is the key benefit of customizing warehouse operations?
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A focused work center is a separate facility.
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Fabrication lines are paced by work tasks.
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Both fabrication lines and assembly lines must be balanced.
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Focused work cells are organized by product line.
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Assembly lines build components on a series of machines.
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Study Notes
Focused Work Center and Focused Factory
- Focused Work Center: a plant within a plant, where cells are organized to focus on specific production tasks, moving away from general-purpose, process-oriented facilities.
- Focused Factory: a separate facility that houses a focused work cell, which can be focused on product lines, layout, quality, new product introduction, flexibility, or other requirements.
Product-Oriented Layouts
- Fabrication line: builds components on a series of machines, machine-paced, and requires mechanical or engineering changes to balance.
- Assembly line: puts fabricated parts together at a series of workstations, paced by work tasks, and balanced by moving tasks.
Advantages of Product-Oriented Layouts
- Advantages of fabrication and assembly lines include balanced production, reduced waste, and improved efficiency.
Computer Software in Layout Planning
- Three-dimensional visualization software helps managers view possible layouts, assess process, material handling, efficiency, and safety issues.
Focused Facilities
- Focused facilities are designed to match customer requirements and demand, reducing waste and capacity requirements.
- They are suitable for a family of similar products with reasonably stable demand.
Work Cells
- Work cells reorganize people and machines into groups to focus on single products or product groups.
- Group technology identifies products with similar characteristics for particular cells.
- Volume must justify the creation of cells, and cells can be reconfigured as designs or volume changes.
Requirements of Work Cells
- Identification of families of products is necessary.
- A high level of training, flexibility, and empowerment of employees is required.
- Work cells should be self-contained, with their own equipment and resources.
- Testing (poka-yoke) should be performed at each station in the cell.
Advantages of Work Cells
- Reduced work-in-process inventory
- Less floor space required
- Reduced raw material and finished goods inventories
- Reduced direct labor cost
- Heightened sense of employee participation
- Increased equipment and machinery utilization
- Reduced investment in machinery and equipment
Warehouse and Storage Layouts
- The objective is to find the optimum trade-offs between handling costs and costs associated with warehouse space.
- Maximize the total "cube" of the warehouse, utilizing its full volume while maintaining low material handling costs.
Warehousing and Storage Layouts
- Warehouse density tends to vary inversely with the number of different items stored.
- Automated Storage and Retrieval Systems (ASRSs) can significantly improve warehouse productivity.
- Dock location is a key design element.
Cross-Docking
- Materials are moved directly from receiving to shipping, without being placed in storage in the warehouse.
- Requires tight scheduling and accurate shipments, with bar code or RFID identification used for advanced shipment notification.
Random Stocking
- Typically requires automatic identification systems (AISs) and effective information systems.
- Allows more efficient use of space.
- Key tasks include:
- Maintaining a list of “open” locations
- Maintaining accurate records
- Sequencing items to minimize travel, “pick” time
- Combining picking orders
- Assigning classes of items to particular areas
Customizing
- Value-added activities performed at the warehouse, enabling low-cost and rapid response strategies.
- Examples include:
- Assembly of components
- Loading software
- Repairs
- Customized labeling and packaging
Focused Work Center and Focused Factory
- Focused Work Center: a plant within a plant, where cells are organized to focus on specific production tasks, moving away from general-purpose, process-oriented facilities.
- Focused Factory: a separate facility that houses a focused work cell, which can be focused on product lines, layout, quality, new product introduction, flexibility, or other requirements.
Product-Oriented Layouts
- Fabrication line: builds components on a series of machines, machine-paced, and requires mechanical or engineering changes to balance.
- Assembly line: puts fabricated parts together at a series of workstations, paced by work tasks, and balanced by moving tasks.
Advantages of Product-Oriented Layouts
- Advantages of fabrication and assembly lines include balanced production, reduced waste, and improved efficiency.
Computer Software in Layout Planning
- Three-dimensional visualization software helps managers view possible layouts, assess process, material handling, efficiency, and safety issues.
Focused Facilities
- Focused facilities are designed to match customer requirements and demand, reducing waste and capacity requirements.
- They are suitable for a family of similar products with reasonably stable demand.
Work Cells
- Work cells reorganize people and machines into groups to focus on single products or product groups.
- Group technology identifies products with similar characteristics for particular cells.
- Volume must justify the creation of cells, and cells can be reconfigured as designs or volume changes.
Requirements of Work Cells
- Identification of families of products is necessary.
- A high level of training, flexibility, and empowerment of employees is required.
- Work cells should be self-contained, with their own equipment and resources.
- Testing (poka-yoke) should be performed at each station in the cell.
Advantages of Work Cells
- Reduced work-in-process inventory
- Less floor space required
- Reduced raw material and finished goods inventories
- Reduced direct labor cost
- Heightened sense of employee participation
- Increased equipment and machinery utilization
- Reduced investment in machinery and equipment
Warehouse and Storage Layouts
- The objective is to find the optimum trade-offs between handling costs and costs associated with warehouse space.
- Maximize the total "cube" of the warehouse, utilizing its full volume while maintaining low material handling costs.
Warehousing and Storage Layouts
- Warehouse density tends to vary inversely with the number of different items stored.
- Automated Storage and Retrieval Systems (ASRSs) can significantly improve warehouse productivity.
- Dock location is a key design element.
Cross-Docking
- Materials are moved directly from receiving to shipping, without being placed in storage in the warehouse.
- Requires tight scheduling and accurate shipments, with bar code or RFID identification used for advanced shipment notification.
Random Stocking
- Typically requires automatic identification systems (AISs) and effective information systems.
- Allows more efficient use of space.
- Key tasks include:
- Maintaining a list of “open” locations
- Maintaining accurate records
- Sequencing items to minimize travel, “pick” time
- Combining picking orders
- Assigning classes of items to particular areas
Customizing
- Value-added activities performed at the warehouse, enabling low-cost and rapid response strategies.
- Examples include:
- Assembly of components
- Loading software
- Repairs
- Customized labeling and packaging
Three-Dimensional Visualization Software
- Allows managers to view possible layouts and assess process, material handling, efficiency, and safety issues
Focused Facilities
- A family of similar products with reasonably stable demand
- Match facilities to customer requirements and demand
- Reduces waste and capacity requirements
Work Cells
- Reorganizes people and machines into groups to focus on single products or product groups
- Group technology identifies products that have similar characteristics for particular cells
- Volume must justify cells
- Cells can be reconfigured as designs or volume changes
Requirements of Work Cells
- Identification of families of products
- A high level of training, flexibility, and empowerment of employees
- Self-contained, with its own equipment and resources
- Testing (poka-yoke) at each station in the cell
Advantages of Work Cells
- Reduced work-in-process inventory
- Less floor space required
- Reduced raw material and finished goods inventories
- Reduced direct labor cost
- Heightened sense of employee participation
- Increased equipment and machinery utilization
- Reduced investment in machinery and equipment
Warehouse and Storage Layouts
- Objective is to find the optimum trade-offs between handling costs and costs associated with warehouse space
- Maximize the total "cube" of the warehouse – utilize its full volume while maintaining low material handling costs
Warehousing and Storage Layouts
- Warehouse density tends to vary inversely with the number of different items stored
- Automated Storage and Retrieval Systems (ASRSs) can significantly improve warehouse productivity
- Dock location is a key design element
Cross-Docking
- Materials are moved directly from receiving to shipping and are not placed in storage in the warehouse
- Requires tight scheduling and accurate shipments, bar code or RFID identification used for advanced shipment notification as materials are unloaded
Random Stocking
- Typically requires automatic identification systems (AISs) and effective information systems
- Allows more efficient use of space
- Key tasks include:
- Maintaining a list of “open” locations
- Maintaining accurate records
- Sequencing items to minimize travel, “pick” time
- Combining picking orders
- Assigning classes of items to particular areas
Customizing
- Value-added activities performed at the warehouse
- Enables low-cost and rapid response strategies
- Activities include:
- Assembly of components
- Loading software
- Repairs
- Customized labeling and packaging
Focused Work Center and Focused Factory
- Focused Work Center:
- Cells may be organized as focused work centers – plant within a plant
- Moves production from a general-purpose, process-oriented facility to a large work cell
- Focused Factory:
- A focused work cell in a separate facility
- May be focused by product line, layout, quality, new product introduction, flexibility, or other requirements
Product-Oriented Layouts
- Fabrication line:
- Builds components on a series of machines
- Machine-paced
- Require mechanical or engineering changes to balance
- Assembly line:
- Puts fabricated parts together at a series of workstations
- Paced by work tasks
- Balanced by moving tasks
- Both types of lines must be balanced so that the time to perform the work at each station is the same
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Description
Learn about organized plant cells for specific production tasks and separate facilities for focused work cells in operations management. Explore the principles and benefits of focused work centers and focused factories.
