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Production and Operations Management
Unit 12
________________________________________________________________________________
Unit 12:
Plant Layout and Material Handling
Structure 12.1 Introduction Balancing for Material Flow 12.2.1 The Line Balancing Problem 12.2.2 Johnson’s Algorithm of Sequencing 12.2.3 CDS Algorithm for n jobs on m machines 12.3 Principles, Practices and Advanced Analysis for order picking 12.3.1 Equipments 12.3.2 Design Consideration 12.4 Considerations when planning and implementing Integrated Material Handling Systems 12.5 Ergonomics and Material Handling: A task oriented Assessment of Needs and Solutions 12.6 Approaches for Shop Floor Sequencing of Material Handling Jobs 12.7 Summary TQ Answer to SAQs and TQs 12.1 Introduction Material handling has become one of the important functions of Operations Management owing to the necessity of making them efficient and economical. This necessity is the outcome of worldwide outsourcing and meeting the demands of a global market. Variety and volumes have compelled companies to seek specialized suppliers from various countries. Assemblies take place at different locations and distribution is across the world. Many companies do not have ‘main stores’ at their manufacturing facilities. Suppliers deliver the required quantities to the places where they are required for further processing or assembly. To reduce inventory only required quantities have to be made and delivered at appropriate times. This necessitates that flow lines are smooth. Balancing
______________________________________________________________________________ Sikkim Manipal University
173
Production and Operations Management
Unit 12
________________________________________________________________________________ flow lines, different equipments to achieve the same and preparing layouts to achieve these is the subject matter of this unit.
Learning Objectives : After Studying this Unit you will 1. Know the importance of a good layout in enabling efficient material handling; 2. understand the principles involved in deg Integrated Material Handling Systems 3. appreciate the importance of the way human body is subjected to different forces when performing various actions during material handling 4. know how material flow is regulated so that balancing of work loads becomes efficient. 12.2 Balancing for Material Flow
Production lines have a number of workcentres in a
particular sequence so that the material that gets processed has to move further without encountering any bottlenecks. The quantities produced, the rate of production at each center, the number of operations and the total production required are factors taken into . The purpose of balancing is to see that no shortages occur between workcentres and minimum inventory gets created. We use the principles of JIT and Lean Manufacturing to achieve these. Linear Programming, dynamic programming and other mathematical models are used to study these problems. Some computerefficient approximate algorithms have been developed to help the process. 12.2.1 The Line Balancing Problem
Assembly lines are best suited for the study and
analysis of the Line Balancing Problem called Assembly Line Balancing ( ALB ). All ALB are categorized by Ghosh and Gagnon as to falling into four categories as under: SMD Single Model Deterministic This model assumes that the one product that es through the dedicated line has all tasks times known. This model is useful when automatic machines or where operations have their times predictable with certainty. SMS
Single Model Stochastic This models allows the task times to be variable. This is
applicable when a single product goes through machines where manual content is more and the operations do not have definite periods. Determining locations and sizes of buffers require to keep the throughput is the purpose of this algorithm.
______________________________________________________________________________ Sikkim Manipal University
174
Production and Operations Management
Unit 12
________________________________________________________________________________ MMD Multi/Mixed Model Deterministic : In this case task times are known, but we have many products that go through the line. The products are assembled in batches. MMS Multi/Mixed Model Stochastic : The task times are variable and we have many products that go through the production line. The problems of balancing such lines is more. Decomposition of the assembly into subassemblies and having advanced handling equipment may help to make inventories small keeping the flow line smooth. Generally the criteria for all the above cases are technical and economic ones. The technical criterion seeks to maximize the line efficiency throughput. Minimising the number of workstations, number of operators and reducing the quantum of buffers are the economic criteria. Many times a trade off may be necessary. It is for the operations manager to balance between two competing requirements.
12.2.2 Johnson’s Algorithm of Sequencing This algorithm is used for sequencing of n jobs through two work centres. The purpose is to minimize idle time on machines and reduce the total time taken for completing all the jobs. There are no priority rules since all job have equal priority. The The order of the operations will be machine1 first and machine2 next. The steps to be taken are: (i)
Choose the job which has the shortest processing time in any of the two workcentres.
(ii)
If it happens to be on machine 1, then load it first; if it is on machine 2, allot it for loading last.
(iii)
Eliminate this job. Continue this till all jobobleobs have been allotted.
Example: Time on
______________________________________________________________________________ Sikkim Manipal University
175
Production and Operations Management
Unit 12
________________________________________________________________________________ Job
M/c 1
M/c 2
A
2.5
1.5
B
3.5
2.0
C
1
3.25
D
2.25
2.75
E
3.75
1.75
F
1.25
4.0
Time 1 Hr. is on M/c1 load it first. Cancel the row which contains 1 and 3.25. The job is C Next, time 1.25 is on M/c1. Load job F next. The next is 1.5 which is on M/c. 2 . Load it last. The job is E ,, continue…
The loading sequence is given in the box below C
F
B
D
E
A
In case the periods on two machines for any of the jobs is the same, you may choose either of them for applying the above rule
12.2.3 CDS Alogrithm for n jobs on m machines : This algorithm given by Campbell, Dudek and Smith, gives m1 solutions and we can choose the most optimal among them. We will use the Johnson’s rule by converting the number of machines from m to 2, by considering differing combinations – like 1 and m, then1+2 , then M1 and M, then 1+2+3 and a M2, M1 and M, and so on. This process is useful, when th numbers of machines is small. We will work out a problem when we have 4 machines.
______________________________________________________________________________ Sikkim Manipal University
176
Production and Operations Management
Unit 12
________________________________________________________________________________
Example: Time on Machines in Hrs. Job
M1
M2
M3
Take column M1 and M4, ignoring M2 and M3. Get the sequence by applying Johnson’s rule Next Combine M1 and M2 Make it as one machine MX and combne M3 and M4 and call it MY. Get the sequence. Next Combine M1 and M2 and M3 and call it MC . Similarly combine M2 and M3 and M4. Call it MD. Find the sequence. Calculate the total time taken to process all jobs A, B C, D and E. Choose whichever given the total time.
M4
A 6 8 7 4 B 4 5 3 6 C 5 5 7 3 D 3 4 6 2 E 4
3 4 7
The first table will be Machining Time Job
B
M1
M4
A
6
4
B
4
6
C
5
3
D
3
2
E
4
7
E
A
C
D
Calculate the total time taken when this sequence is followed. , that except for M1, other machines may have to wait to start their operations, until the previous operation is over. You have to include idle times at the beginning, middle or the end.
______________________________________________________________________________ Sikkim Manipal University
177
Production and Operations Management
Unit 12
________________________________________________________________________________ 12.3 Principles, Practices and Advanced Analysis for order picking – Order Picking is a process by which items or products for which supply is to be made have to be retrieved from specific storage location. It is found to take 60% of labour activities in the warehouse. Since it is critical to business to the meet customer’s demand expeditiously and accurately, lot of attention is being given to this aspect of operations. In the manufacturing arena, we desire to move towards small lot sizes, pointofusedelivery and cycle time reductions. These are necessary to meet the targets of JIT, which have economic implications. Efficient order picking is necessary for being competitive. In the supply chain, storage, retrieval and delivery do not add value to the product, but are necessary.
12.3.1 Equipments
First we will see the types of equipments that help us in bring in
efficiency to the process. (a) Horizontal Travel These are in the aisle, picker to part systems The picker – a worker – walks or rides a vehicle and picks the item or product and puts into the cart or vehicle. He may also pick an place the item on a conveyor. The storage system could be pallet racks, shelves, storage drawers or gravity flow racks. The pallet racks can be only one or two levels. (b) Person Aboard – In this system the picker is on a platform of the vehicle; he can move up as also horizontally along the aisle. (c) Part to Picker These are mechanized systems. Here a storage/retrievel device carries the trays or bins to the person picking. These act on the instructions received through a remote control device with the picker. More than one picker can also access the system. (d) Special equipment For high throughput and space efficiency special equipment are made which are in the form of moveable shelves, rotary racks, mobile shuttles that travel in lanes or even an automatic item picker which has dispensing mechanisms that eject items on a conveyor belt. (e) Workplace Equipment Items can be kept on a work bench and be picked up. The carts also are used to keep items for being picked up. It should be noted that any of the systems described above are to suit the purpose and economies that can be derived. Before implementing any of these a detailed study of alternatives, a plan for expansion or reduction in the requirement of a particular product or a
______________________________________________________________________________ Sikkim Manipal University
178
Production and Operations Management
Unit 12
________________________________________________________________________________ probable shifting of the location etc. will have to be undertaken. Some of these factors are listed below: A.
Material properties
size, weight and nestability
carton counts, pallet counts
fragility,
value
fragility
environment – temperature, humidity
B.
System Requirements for the product
Volume per product
Number of order to be shipped
Response time
ing processes – labeling, pricing,
Growth factors
C.
Economic Factors
Investment Required
Project life
Rate of return
12.3.2 Design Considerations Design considerations arise, mainly out of the following. Some of the factors mentioned above also are relevant for the purpose of design. They are a)
Total number of products that are to be stored
b)
Number of products received per shift
c)
Total numbers retrieved per shift
d)
Variability in the above
These will determine the dimensions of the building required for
the purpose. Sizes of bins, racks, pallets are also fixed on the basis of above. Choice between carts, carousals, vehicles, conveyors, automatic item pickers can be made as also the space for locating and moving them. e)
Labour force
f)
Management Information System.
______________________________________________________________________________ Sikkim Manipal University
179
Production and Operations Management
Unit 12
________________________________________________________________________________
Self Assessment Questions 1 1. In the supply chain, storage, retrieval and delivery do not add value to the product, but are necessary. ( True / False )
12.4 Considerations when planning and implementing Integrated Material Handling
Systems
Material handling systems need to be made efficient so that resources used help
maintain the flow of material with minimum blockages – bottlenecks – and throughput being maximum. Integration is between various equipments, processes, information and a system of control. Inevitably, we use computer systems and some amount of automation to bring in efficiencies, which otherwise would be lost.
12.5
Ergonomics and Material Handling: A task oriented Assessment of Needs and
Solutions In ergonomics, the body is studied as if it were a machine – the way the limbs move, the knees bend, the hands reach or grip, weights are be lifted at different positions of the back. The dynamic motions that the body and the organs are subjected to are studied with a view to deg the systems so that injuries. Dr. Bill Marris developed, what is famous as , LMM –Lumbar Motion Monitor in a study of low back injury. It allows measurement of the forces at work in bending and twisting. This helps us to make improved decisions regarding job improvements. This is specially helpful in material handling stations where workmen have to lift weights, raise them to awkward potions to find a place, move them, hold them, push them. When the same movements are to be repeated a number of times, knowing the problems the movements can cause, we can design equipments to reduce difficulties faced by the workers. You will that the same considerations were discussed when working on machines was considered. It is worth mentioned a word of caution. Machine shop operations or material handling, we have to assess the need for implementing any methodology, because these would have been worked out by the operators and supervisors over years in different job situations and because it affects them on a personal basis, best practices would have set in. Material handling systems are mostly outsourced and the expertise of the contractor will be of great help. However, the particular needs for the products which are handled by us, the shapes, volumes and the type of handling like lifting, storage, retrieval and loading
______________________________________________________________________________ Sikkim Manipal University
180
Production and Operations Management
Unit 12
________________________________________________________________________________ can be formulated and projected data will be useful. Solutions that are required should be considered for a long term usage as also possible changes that can be anticipated.
12.6
Approaches for Shop Floor Sequencing of Material Handling Jobs
Sequencing decides the order in which jobs are loaded on different machines. The purpose is to take the job through the technological steps in which the processing needs to be done for the transformation that is to be effected on the material that is getting processed. The major concerns are about the quantities that need to be processed and the time that the different operations require. In case the product has to enter assembly, along with other parts that are being manufactured parallely , will all the required parts arrive at that point at the same time. Some components may be outsourced. To handle different parts, we have material handling equipments such as cranes, lifting forks, trucks etc. The problem for the manager is the limited supply of these equipments and the need to optimize utilization of the equipment and see that the manufacturing line has smooth flow. Our concern is to reduced inventory, minimum movement and timely availability. This needs an integration of information about all the factors and make decisions which accommodate and optimise utilisation of resources.
Self Assessment Questions 2. 1.
Material handling systems are mostly ___________ and the ___________ of the contractor
will be of great help.
12.7 Summary In this Unit we have considered various factors that affect the layout of the manufacturing place to provide for efficient utilization of the floor space vis a vis workflow. For sequencing of jobs Johnson’s Algorithm is a useful staring point and more advanced methodologies are also available. Balancing the production is a very important aspect of achieving maximum throughput and reducing inventory. Material handling systems are also considered.
______________________________________________________________________________ Sikkim Manipal University
181
Production and Operations Management
Unit 12
________________________________________________________________________________
Terminal Questions
1. What do you understand by Line Balancing? 2. What is the importance of order picking in material handling? 3. Material movement in a manufacturing plan considers economics important. Why? How are its principles applied?
4. Describe a successful computer integrated material handling system. 5. Explain Johnson’s rule for sequencing and how it is different from CDS algorithm Answers for Self Assessment Questions Self Assessment Questions1 1. True Self Assessment Questions 2 1. Outsourced, Expertise Answers for Terminal Questions. 1.Refer to unit 12.2.1 2. Refer to unit 12.3 3. Refer to unit 12.5 4. Refer to unit 12.5 5. Refer to unit . 12.2
______________________________________________________________________________ Sikkim Manipal University
182
Unit 12
________________________________________________________________________________
Unit 12:
Plant Layout and Material Handling
Structure 12.1 Introduction Balancing for Material Flow 12.2.1 The Line Balancing Problem 12.2.2 Johnson’s Algorithm of Sequencing 12.2.3 CDS Algorithm for n jobs on m machines 12.3 Principles, Practices and Advanced Analysis for order picking 12.3.1 Equipments 12.3.2 Design Consideration 12.4 Considerations when planning and implementing Integrated Material Handling Systems 12.5 Ergonomics and Material Handling: A task oriented Assessment of Needs and Solutions 12.6 Approaches for Shop Floor Sequencing of Material Handling Jobs 12.7 Summary TQ Answer to SAQs and TQs 12.1 Introduction Material handling has become one of the important functions of Operations Management owing to the necessity of making them efficient and economical. This necessity is the outcome of worldwide outsourcing and meeting the demands of a global market. Variety and volumes have compelled companies to seek specialized suppliers from various countries. Assemblies take place at different locations and distribution is across the world. Many companies do not have ‘main stores’ at their manufacturing facilities. Suppliers deliver the required quantities to the places where they are required for further processing or assembly. To reduce inventory only required quantities have to be made and delivered at appropriate times. This necessitates that flow lines are smooth. Balancing
______________________________________________________________________________ Sikkim Manipal University
173
Production and Operations Management
Unit 12
________________________________________________________________________________ flow lines, different equipments to achieve the same and preparing layouts to achieve these is the subject matter of this unit.
Learning Objectives : After Studying this Unit you will 1. Know the importance of a good layout in enabling efficient material handling; 2. understand the principles involved in deg Integrated Material Handling Systems 3. appreciate the importance of the way human body is subjected to different forces when performing various actions during material handling 4. know how material flow is regulated so that balancing of work loads becomes efficient. 12.2 Balancing for Material Flow
Production lines have a number of workcentres in a
particular sequence so that the material that gets processed has to move further without encountering any bottlenecks. The quantities produced, the rate of production at each center, the number of operations and the total production required are factors taken into . The purpose of balancing is to see that no shortages occur between workcentres and minimum inventory gets created. We use the principles of JIT and Lean Manufacturing to achieve these. Linear Programming, dynamic programming and other mathematical models are used to study these problems. Some computerefficient approximate algorithms have been developed to help the process. 12.2.1 The Line Balancing Problem
Assembly lines are best suited for the study and
analysis of the Line Balancing Problem called Assembly Line Balancing ( ALB ). All ALB are categorized by Ghosh and Gagnon as to falling into four categories as under: SMD Single Model Deterministic This model assumes that the one product that es through the dedicated line has all tasks times known. This model is useful when automatic machines or where operations have their times predictable with certainty. SMS
Single Model Stochastic This models allows the task times to be variable. This is
applicable when a single product goes through machines where manual content is more and the operations do not have definite periods. Determining locations and sizes of buffers require to keep the throughput is the purpose of this algorithm.
______________________________________________________________________________ Sikkim Manipal University
174
Production and Operations Management
Unit 12
________________________________________________________________________________ MMD Multi/Mixed Model Deterministic : In this case task times are known, but we have many products that go through the line. The products are assembled in batches. MMS Multi/Mixed Model Stochastic : The task times are variable and we have many products that go through the production line. The problems of balancing such lines is more. Decomposition of the assembly into subassemblies and having advanced handling equipment may help to make inventories small keeping the flow line smooth. Generally the criteria for all the above cases are technical and economic ones. The technical criterion seeks to maximize the line efficiency throughput. Minimising the number of workstations, number of operators and reducing the quantum of buffers are the economic criteria. Many times a trade off may be necessary. It is for the operations manager to balance between two competing requirements.
12.2.2 Johnson’s Algorithm of Sequencing This algorithm is used for sequencing of n jobs through two work centres. The purpose is to minimize idle time on machines and reduce the total time taken for completing all the jobs. There are no priority rules since all job have equal priority. The The order of the operations will be machine1 first and machine2 next. The steps to be taken are: (i)
Choose the job which has the shortest processing time in any of the two workcentres.
(ii)
If it happens to be on machine 1, then load it first; if it is on machine 2, allot it for loading last.
(iii)
Eliminate this job. Continue this till all jobobleobs have been allotted.
Example: Time on
______________________________________________________________________________ Sikkim Manipal University
175
Production and Operations Management
Unit 12
________________________________________________________________________________ Job
M/c 1
M/c 2
A
2.5
1.5
B
3.5
2.0
C
1
3.25
D
2.25
2.75
E
3.75
1.75
F
1.25
4.0
Time 1 Hr. is on M/c1 load it first. Cancel the row which contains 1 and 3.25. The job is C Next, time 1.25 is on M/c1. Load job F next. The next is 1.5 which is on M/c. 2 . Load it last. The job is E ,, continue…
The loading sequence is given in the box below C
F
B
D
E
A
In case the periods on two machines for any of the jobs is the same, you may choose either of them for applying the above rule
12.2.3 CDS Alogrithm for n jobs on m machines : This algorithm given by Campbell, Dudek and Smith, gives m1 solutions and we can choose the most optimal among them. We will use the Johnson’s rule by converting the number of machines from m to 2, by considering differing combinations – like 1 and m, then1+2 , then M1 and M, then 1+2+3 and a M2, M1 and M, and so on. This process is useful, when th numbers of machines is small. We will work out a problem when we have 4 machines.
______________________________________________________________________________ Sikkim Manipal University
176
Production and Operations Management
Unit 12
________________________________________________________________________________
Example: Time on Machines in Hrs. Job
M1
M2
M3
Take column M1 and M4, ignoring M2 and M3. Get the sequence by applying Johnson’s rule Next Combine M1 and M2 Make it as one machine MX and combne M3 and M4 and call it MY. Get the sequence. Next Combine M1 and M2 and M3 and call it MC . Similarly combine M2 and M3 and M4. Call it MD. Find the sequence. Calculate the total time taken to process all jobs A, B C, D and E. Choose whichever given the total time.
M4
A 6 8 7 4 B 4 5 3 6 C 5 5 7 3 D 3 4 6 2 E 4
3 4 7
The first table will be Machining Time Job
B
M1
M4
A
6
4
B
4
6
C
5
3
D
3
2
E
4
7
E
A
C
D
Calculate the total time taken when this sequence is followed. , that except for M1, other machines may have to wait to start their operations, until the previous operation is over. You have to include idle times at the beginning, middle or the end.
______________________________________________________________________________ Sikkim Manipal University
177
Production and Operations Management
Unit 12
________________________________________________________________________________ 12.3 Principles, Practices and Advanced Analysis for order picking – Order Picking is a process by which items or products for which supply is to be made have to be retrieved from specific storage location. It is found to take 60% of labour activities in the warehouse. Since it is critical to business to the meet customer’s demand expeditiously and accurately, lot of attention is being given to this aspect of operations. In the manufacturing arena, we desire to move towards small lot sizes, pointofusedelivery and cycle time reductions. These are necessary to meet the targets of JIT, which have economic implications. Efficient order picking is necessary for being competitive. In the supply chain, storage, retrieval and delivery do not add value to the product, but are necessary.
12.3.1 Equipments
First we will see the types of equipments that help us in bring in
efficiency to the process. (a) Horizontal Travel These are in the aisle, picker to part systems The picker – a worker – walks or rides a vehicle and picks the item or product and puts into the cart or vehicle. He may also pick an place the item on a conveyor. The storage system could be pallet racks, shelves, storage drawers or gravity flow racks. The pallet racks can be only one or two levels. (b) Person Aboard – In this system the picker is on a platform of the vehicle; he can move up as also horizontally along the aisle. (c) Part to Picker These are mechanized systems. Here a storage/retrievel device carries the trays or bins to the person picking. These act on the instructions received through a remote control device with the picker. More than one picker can also access the system. (d) Special equipment For high throughput and space efficiency special equipment are made which are in the form of moveable shelves, rotary racks, mobile shuttles that travel in lanes or even an automatic item picker which has dispensing mechanisms that eject items on a conveyor belt. (e) Workplace Equipment Items can be kept on a work bench and be picked up. The carts also are used to keep items for being picked up. It should be noted that any of the systems described above are to suit the purpose and economies that can be derived. Before implementing any of these a detailed study of alternatives, a plan for expansion or reduction in the requirement of a particular product or a
______________________________________________________________________________ Sikkim Manipal University
178
Production and Operations Management
Unit 12
________________________________________________________________________________ probable shifting of the location etc. will have to be undertaken. Some of these factors are listed below: A.
Material properties
size, weight and nestability
carton counts, pallet counts
fragility,
value
fragility
environment – temperature, humidity
B.
System Requirements for the product
Volume per product
Number of order to be shipped
Response time
ing processes – labeling, pricing,
Growth factors
C.
Economic Factors
Investment Required
Project life
Rate of return
12.3.2 Design Considerations Design considerations arise, mainly out of the following. Some of the factors mentioned above also are relevant for the purpose of design. They are a)
Total number of products that are to be stored
b)
Number of products received per shift
c)
Total numbers retrieved per shift
d)
Variability in the above
These will determine the dimensions of the building required for
the purpose. Sizes of bins, racks, pallets are also fixed on the basis of above. Choice between carts, carousals, vehicles, conveyors, automatic item pickers can be made as also the space for locating and moving them. e)
Labour force
f)
Management Information System.
______________________________________________________________________________ Sikkim Manipal University
179
Production and Operations Management
Unit 12
________________________________________________________________________________
Self Assessment Questions 1 1. In the supply chain, storage, retrieval and delivery do not add value to the product, but are necessary. ( True / False )
12.4 Considerations when planning and implementing Integrated Material Handling
Systems
Material handling systems need to be made efficient so that resources used help
maintain the flow of material with minimum blockages – bottlenecks – and throughput being maximum. Integration is between various equipments, processes, information and a system of control. Inevitably, we use computer systems and some amount of automation to bring in efficiencies, which otherwise would be lost.
12.5
Ergonomics and Material Handling: A task oriented Assessment of Needs and
Solutions In ergonomics, the body is studied as if it were a machine – the way the limbs move, the knees bend, the hands reach or grip, weights are be lifted at different positions of the back. The dynamic motions that the body and the organs are subjected to are studied with a view to deg the systems so that injuries. Dr. Bill Marris developed, what is famous as , LMM –Lumbar Motion Monitor in a study of low back injury. It allows measurement of the forces at work in bending and twisting. This helps us to make improved decisions regarding job improvements. This is specially helpful in material handling stations where workmen have to lift weights, raise them to awkward potions to find a place, move them, hold them, push them. When the same movements are to be repeated a number of times, knowing the problems the movements can cause, we can design equipments to reduce difficulties faced by the workers. You will that the same considerations were discussed when working on machines was considered. It is worth mentioned a word of caution. Machine shop operations or material handling, we have to assess the need for implementing any methodology, because these would have been worked out by the operators and supervisors over years in different job situations and because it affects them on a personal basis, best practices would have set in. Material handling systems are mostly outsourced and the expertise of the contractor will be of great help. However, the particular needs for the products which are handled by us, the shapes, volumes and the type of handling like lifting, storage, retrieval and loading
______________________________________________________________________________ Sikkim Manipal University
180
Production and Operations Management
Unit 12
________________________________________________________________________________ can be formulated and projected data will be useful. Solutions that are required should be considered for a long term usage as also possible changes that can be anticipated.
12.6
Approaches for Shop Floor Sequencing of Material Handling Jobs
Sequencing decides the order in which jobs are loaded on different machines. The purpose is to take the job through the technological steps in which the processing needs to be done for the transformation that is to be effected on the material that is getting processed. The major concerns are about the quantities that need to be processed and the time that the different operations require. In case the product has to enter assembly, along with other parts that are being manufactured parallely , will all the required parts arrive at that point at the same time. Some components may be outsourced. To handle different parts, we have material handling equipments such as cranes, lifting forks, trucks etc. The problem for the manager is the limited supply of these equipments and the need to optimize utilization of the equipment and see that the manufacturing line has smooth flow. Our concern is to reduced inventory, minimum movement and timely availability. This needs an integration of information about all the factors and make decisions which accommodate and optimise utilisation of resources.
Self Assessment Questions 2. 1.
Material handling systems are mostly ___________ and the ___________ of the contractor
will be of great help.
12.7 Summary In this Unit we have considered various factors that affect the layout of the manufacturing place to provide for efficient utilization of the floor space vis a vis workflow. For sequencing of jobs Johnson’s Algorithm is a useful staring point and more advanced methodologies are also available. Balancing the production is a very important aspect of achieving maximum throughput and reducing inventory. Material handling systems are also considered.
______________________________________________________________________________ Sikkim Manipal University
181
Production and Operations Management
Unit 12
________________________________________________________________________________
Terminal Questions
1. What do you understand by Line Balancing? 2. What is the importance of order picking in material handling? 3. Material movement in a manufacturing plan considers economics important. Why? How are its principles applied?
4. Describe a successful computer integrated material handling system. 5. Explain Johnson’s rule for sequencing and how it is different from CDS algorithm Answers for Self Assessment Questions Self Assessment Questions1 1. True Self Assessment Questions 2 1. Outsourced, Expertise Answers for Terminal Questions. 1.Refer to unit 12.2.1 2. Refer to unit 12.3 3. Refer to unit 12.5 4. Refer to unit 12.5 5. Refer to unit . 12.2
______________________________________________________________________________ Sikkim Manipal University
182
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