This document discusses lean manufacturing systems and factors influencing facility layout designs. It describes the main types of layouts including process, product, and fixed-position layouts as well as hybrid layouts like cellular manufacturing, flexible manufacturing systems, and mixed-model assembly lines. The goals of layout design are to ensure smooth material and information flow while arranging machines, departments, workstations, and storage areas. Process layouts group similar activities together and are suitable for low-volume production, while product layouts arrange activities in operational sequence for mass production. Hybrid layouts aim to balance the flexibility of process layouts with the efficiency of product layouts.

1. LEAN MANUFACTURING SYSTEMS
Manufacturing System Design
By:
Kiran Hanjar S
1MS12MIA03
III Sem, IE (M.Tech)
Dept. of IEM, MSRIT
Department of IEM, MSRIT
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2. Factors influencing the system designs in an
emerging industrial space
 More companies serve global markets by making products for customers
worldwide.
 As production of a variety of products increases, decreases in lot sizes and
quantities result.
 Requirements for closer tolerances continue to increase. Requirements demand
higher levels of accuracy, precision, and quality.
 Product reliability is increasing in response to excessive product liability
lawsuits.
 The time between an initial design concept and a resulting product continues to
shorten due to concurrent or simultaneous engineering.
 Ergonomics and worker safety continue to grow in importance as workercompensation costs escalate and humanistic trends continue
 Green manufacturing strategies continue to help protect the earth from further
pollution
Department of IEM, MSRIT
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3. Introduction
 Facility Layout and Work Flow
 Arrangement within a factory of:
 Machines
 Departments
 Workstations
 Storage areas
 Aisles and common areas
 Ensures a smooth flow of work, material, people and information
through the system
Department of IEM, MSRIT
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4. Types of Layouts
• 3 three basic types of layout:
• Process layout
• Product layout
• Fixed-Position layout
• 3 hybrid layouts:
• Cellular Manufacturing
• Flexible Manufacturing Systems
• Mixed-model Assembly Lines
Department of IEM, MSRIT
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5. Process Layout
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Similar activities grouped together in work areas
Suitable for low volume or batch production
Flexible
Not very efficient
Storage space – large receiving, small shipping
Large aisles for movement of material
Drilling Department
Milling Department
Lathe Department
D
L
L
L
L
L
M
L
M
D
D
D
M
D
D
D
D
Grinding Department
G
G
G
Painting Department
P
G
P
L
L
Receiving and Shipping
Department of IEM, MSRIT
Assembly
A
A
A
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6. Product Layout
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Arrange activities in sequence of operation
Line set up for one product
Specialised machines
Suitable for mass production
More automated than process layouts
Efficient
Line flow – avoid bottlenecks
IN
Not flexible
Department of IEM, MSRIT
OUT
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7. Fixed Position Layout
• Large projects too big to move
• Equipment and parts moved in and out of work area
• Highly skilled workers - costly
Department of IEM, MSRIT
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8. Hybrid Layouts
Try to mix flexibility of process layout with efficiency of
product layout
Cellular Layouts:
• Machines grouped into cells
• Cells process parts with similar features
• Work cell resembles a small assembly line (product)
• Layout between cells treated as process layout
Department of IEM, MSRIT
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9. Comparison
Design of work cell
Processed based layout
Assembly
4
6
Assembly
7
5
9
4
8
8
1
0
2
2
1
1
0
3
1
2
9
6
1
3
1
1
1
2
1
1
Raw
Materials
Department of IEM, MSRIT
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Raw
Materials
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10. Flexible Manufacturing Systems
• Automates the entire manufacture of a product
• Very costly
• Complex software
• Small number of FMS worldwide
• Flexible Manufacturing Cell:
• Smaller version of FMS
• One manufacturing process is automated
Department of IEM, MSRIT
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11. Progressive FMS
• Progressive FMS:
• All parts follow same progression through the work stations
• Best where group technology can be applied
Unload Station
Department of IEM, MSRIT
Load Station
Pallet
Progressive FMS
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12. Closed Loop FMS
• Larger variety of parts
• Parts can follow different paths
• Parts can skip stations
Load
Unload
Pallet
Closed Loop FMS
Department of IEM, MSRIT
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13. Ladder FMS layout
• Parts moved to and from any machine in any
sequence
• More flexible than progressive and closed loop
Load/Unload
systems
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14. Mixed Model Assembly Lines
• More than one product is processed by the line
• Workers trained to work on more than one station
• Layout of line changed
• Long and short operations arranged to cancel each
other
Traditional line
Department of IEM, MSRIT
U Shaped Line
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15. Limitations
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System size and complexity inhibit modeling and control, due to implied-time
expenditures.
Systems are dynamic and unstable. The environment can change the system and vice
versa.
Relationships may be awkward to express in analytical terms, and interactions may be
nonlinear. Thus, well-behaved functions often do not apply.
Data or information may be difficult to secure, inaccurate, conflicting, missing, or too
abundant to digest.
Objectives may be difficult to define, particularly in systems that have an impact on
social and political issues. Goals may conflict.
The act of observing and trying to control a system changes the behavior of the system.
Analysis and control algorithms for systems can be subject to errors of omission and
commission. Some errors will be related to breakdowns or delays in feedback elements.
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16. THANK YOU
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