Chap006 - Chapter 06 - Process Selection and Facilities...

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Chapter 06 - Process Selection and Facilities Layout CHAPTER 6 PROCESS SELECTION AND FACILITIES LAYOUT Teaching Notes Facility Layout involves physical placement of departments and/or arrangement of equipment within a plant or a service facility. A good layout will possibly lead to smooth flow of material, reduction of inventories, and effective utilization of space. The material in this chapter can be divided into four areas: 1. Process types, process selection and automation. 2. Classification of production systems and (corresponding) types of layouts. 3. Line balancing. 4. Designing process layouts. This chapter provides a good lead-in for the following chapter on design of work systems because it introduces some of the problems that can be associated with work systems. It also describes group technology, cellular manufacturing, and flexible manufacturing systems. Operations Tour: Morton Salt 1. Steps in salt production for Morton are: a. Inject water into salt caverns below the surface and let the salt deposits dissolve in the water. b. Pump the resulting brine to the surface. c. Boil the brine, let the liquid evaporate leaving salt crystals and residual moisture. d. Dry the salt to remove the residual moisture. e. Store the salt in silos. f. Move the salt to dedicated production areas. g. Produce the cans by forming a cylinder (two sheets of chip board are glued together) . h. Roll the cylinder into a continuous tube. i. Cut the tubes into can-size pieces. j. Assemble and glue the separate pieces constituting the can. k. Fill the cans with salt. l. Load the filled cans onto pallets and store them in inventory. 6-1
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Chapter 06 - Process Selection and Facilities Layout 2. Quality is checked during different stages of the production process. a. Check salt for purity using chemical analysis. b. Assure appropriate crystal size by forcing the salt through a scraping screen. c. Remove the small pieces of metal by magnets at different stages of the process. d. Check the weight of the filled cans, attach the label sticker. e. Check to make sure that metal pour spouts are correctly attached. 3. The company may not have updated its equipment because of the high cost of investment in new machinery. 4. Salt production would be a low variety, high volume operation which would place it as a repetitive production or continuous flow in the product-process matrix. 5. (3,800,000 cans per year) x (26 ounces of salt per can) = 98,800,000 ounces per year. (98,800,000 ounces per year) / (16 ounces per pound) = 6,175,000 pounds per year. (6,175,000 pounds per year) / (2000 pounds per ton) = 3,087.5 tons of salt per year. 6. Suggested improvements include the following: a. Application of Statistical Process Control (SPC) to reduce the cost of quality. b. Develop a plan to overhaul the existing equipment and to purchase new equipment as a joint effort among finance, purchasing and manufacturing areas.
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Chap006 - Chapter 06 - Process Selection and Facilities...

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