PED 351 Facilities Planning & Material Handling Lecture (5) Flow Systems - Fall 2024 PDF

Faculty of Engineering Production Engineering Department PED 351 Facilities Planning and Material Handling (Fall 2024) Lecture (5): Flow Systems Dr. Hadi Fors Outline Introduction Flow Systems Material Flow System Faculty of Engineering Slide 2 Pro...

Faculty of Engineering Production Engineering Department PED 351 Facilities Planning and Material Handling (Fall 2024) Lecture (5): Flow Systems Dr. Hadi Fors Outline Introduction Flow Systems Material Flow System Faculty of Engineering Slide 2 Production Engineering Department Recall Facilities planning process for manufacturing can be listed as: Define the products to be manufactured. Specify the manufacturing processes and related activities required to produce the products. Determine the interrelationships among all activities. Determine the space requirements for all activities. Generate alternative facilities plans. Evaluate the alternative facilities plans. Select the preferred facilities plan. Implement the facilities plan. Maintain and adapt the facilities plan. Update the products to be manufactured and redefine the objective of the facility. Faculty of Engineering Slide 3 Production Engineering Department Flow Systems Flow can be defined as the movement of goods, materials, energy, information, and/or people. Examples of flows: Product flow: Movement of refrigerators from the manufacturer through various levels of distribution to the ultimate customer. Information flow: Transmission of sales orders from the sales department to the production control department. People flow: Movement of patients, staff, and visitors through a hospital. Flow could be discrete or continuous. Discrete flow: products, orders, people Continuous flow: flow of electric current, flow of oil through a pipeline. Faculty of Engineering Slide 4 Production Engineering Department Flow Systems A flow process may be described in terms of: Subject of flow (item to be processed). Resources that bring about flow (processing and transporting facilities required to accomplish the required flow). Communications that coordinate the resources (procedures that facilitate the management of the flow process). Faculty of Engineering Slide 5 Production Engineering Department Flow Systems Discrete flow systems can be categorized according to the stages of the supply, manufacture, and distribution cycles: Material management system (flow of materials into a manufacturing facility) Material flow system (flow of materials, parts, and supplies within a manufacturing facility) Physical distribution system (flow of products from a manufacturing facility) The above systems may be combined into one overall flow system. Such an overall flow process is referred to as the logistics system. Faculty of Engineering Slide 6 Production Engineering Department Flow Systems Material Management System (MMS) Subjects: materials, parts, and supplies purchased by a firm and required to produce its product. Resources: Vendors Transportation and material handling equipment required to move the materials, parts, and supplies Production control and purchasing departments Receiving, storage, and accounting departments Communications: production forecasts, inventory records, purchase orders, …etc. Faculty of Engineering Slide 7 Production Engineering Department Flow Systems Faculty of Engineering Slide 8 Production Engineering Department Flow Systems Material Flow System (MFS) Subjects: materials, parts, and supplies used by a firm in manufacturing products and components within its facility. Resources: Production control and quality control departments Manufacturing, assembly, and storage departments Material handling equipment required to move materials, parts, and supplies Factory warehouse Communication: production schedules, work order releases, route sheets, assembly charts, and warehouse records,… etc. Faculty of Engineering Slide 9 Production Engineering Department Flow Systems Faculty of Engineering Slide 10 Production Engineering Department Flow Systems Physical Distribution System (PDS) Subjects: finished goods produced by a firm Resources: Sales and accounting departments Factory warehouse Material handling and transportation equipment required to move the finished product Distributors of the finished product Customer Communications: sales orders, picking lists, shipping releases, shipping reports, bill of lading …etc. Faculty of Engineering Slide 11 Production Engineering Department Flow Systems Faculty of Engineering Slide 12 Production Engineering Department Material Flow System Good knowledge of material flow system is of value to the facilities planner because this system define the overall flow environment within which material movement takes place. Flow planning results from an efficient integration of flow patterns and adequate aisles to provide smooth and progressive movement of people, materials, and equipment. Patterns of flow exist within workstations, within departments, and between departments. Efficient material flow design can lower expenses, boost productivity, and prevent delays and bottlenecks. Faculty of Engineering Slide 13 Production Engineering Department Material Flow System Three principles or guidelines can be used to promote effective flow patterns: Maximization of directed flow paths Minimization of flow Minimization of the costs of flow Faculty of Engineering Slide 14 Production Engineering Department Material Flow System Three principles or guidelines can be used to promote effective flow patterns: Maximization of directed flow paths A directed flow path is an uninterrupted flow from origination to destination without any intersection with other paths. Faculty of Engineering Slide 15 Production Engineering Department Material Flow System Three principles or guidelines can be used to promote effective flow patterns: Maximization of directed flow paths A directed flow path is a flow path with no backtracking. Backtracking increases the length of the flow path. Faculty of Engineering Slide 16 Production Engineering Department Material Flow System Three principles or guidelines can be used to promote effective flow patterns: Minimization of flow Flow can be reduced by applying principles of work simplification, including: Eliminating flow by planning for the delivery of materials, information, or people directly to the point of ultimate use and eliminating intermediate steps. Minimizing multiple flows by planning for the flow between two consecutive points of use to take place in as few movements as possible, preferably one. Combining flows and operations wherever possible by planning for the movement of materials, information, or people to be combined with a processing step. Faculty of Engineering Slide 17 Production Engineering Department Material Flow System Three principles or guidelines can be used to promote effective flow patterns: Minimization of costs of flow Minimizing the cost of flow could be achieved through: Eliminate unnecessary material movements Minimize manual handling by minimizing travel distances. Eliminate manual handling by automating flow. Minimize material handling by reducing the flow density through containerization. Faculty of Engineering Slide 18 Production Engineering Department Material Flow System Flow within Workstations Flow within workstations is typically designed to be simultaneous, symmetrical, natural, and rhythmical for worker productivity and comfort. Motion studies and ergonomics considerations are important in establishing the flow within workstations. https://www.ccohs.ca/oshanswers/ergonomics/ Reach zones Work surface height Faculty of Engineering Slide 19 Production Engineering Department Material Flow System Flow within Departments (flow pattern within departments is dependent on the type of department) Flow within a Product Department Flow pattern is according to the product flow End-to-end, back-to-back, and odd-angle flow patterns are used when one operator works at each workstation. Front-to-front flow patterns are used when one operator works on two workstations. Circular flow patterns are used when one operator works on more than two workstations. Faculty of Engineering Slide 20 Production Engineering Department Material Flow System Flow within Departments Flow within a Process Department Minimal amount of flow should occur between workstations within departments. While flow typically occurs between workstations and aisles. Flow patterns are dictated by the orientation of the workstations to the aisles. The determination of the preferred workstation-aisle arrangement pattern is dependent on the interactions among workstation areas, the available space, and the size of the materials to be handled. Faculty of Engineering Slide 21 Production Engineering Department Material Flow System Flow within Departments Flow within Product and Process Departments with Material Handling Considerations Flow patterns within departments will be different in the case of automated systems involving the use of conveyors, automated guided vehicles, robots, and other devices. For these systems, several flow patterns are identified, namely: Line flow Spine flow Loop flow Tree flow Faculty of Engineering Slide 22 Production Engineering Department Material Flow System Flow within Departments Flow within Product and Process Departments with Material Handling Considerations Line Flow Pattern. It is a typical flow pattern found in the automotive industry. Variants of the line flow are shown in the following figure. These variants are used if shorter production line is required. The line flow structure is most effective for assembly line type production. Faculty of Engineering Slide 23 Production Engineering Department Material Flow System Flow within Departments Flow within Product and Process Departments with Material Handling Considerations Spine Flow Pattern. The one-sided/two-sided spine flow patterns are characterized by the presence of a unidirectional or bidirectional material handling device operating along a central spine. The spine flow structure can be used for both within-department flows and between- department flows. Faculty of Engineering Slide 24 Production Engineering Department Material Flow System Flow within Departments Flow within Product and Process Departments with Material Handling Considerations Loop Flow Pattern. The loop flow is characterized by the presence of a loop that services the workstations around it. The flow direction can be unidirectional or bidirectional. The workstations are positioned either in the inside of the loop or along the outside area of the loop. Faculty of Engineering Slide 25 Production Engineering Department Material Flow System Flow within Departments Flow within Product and Process Departments with Material Handling Considerations Tree Flow Pattern. The workstations can be positioned in a single tree or in multiple trees that are linked together by a centralized material handling device. This type of flow structure can be found in facilities that utilize robotic-type material handling for moving parts from workstation to workstation. Faculty of Engineering Slide 26 Production Engineering Department Material Flow System Flow between Departments Used to evaluate overall flow within facility. An important consideration in the flow between departments is the location of the pickup and delivery stations for each department. Faculty of Engineering Slide 27 Production Engineering Department Material Flow System Flow between Departments Several flow patterns or structures could be used to analyze the effectiveness of material movement between departments. Faculty of Engineering Slide 28 Production Engineering Department