Namaskar friends. Welcome to session 24 in
our course on Operations Management and currently we are due in the 5th week of our discussion
on the course. And in every session, I usually revise what we have covered in the previous
sessions. And today also I will not deviate from the, we can say tradition; I will again
try to revise what we have already covered, but very briefly. We have seen the fundamental
aspect that is the scopes, objectives, functions, types of production systems in our week 1;
in which we have covered the introduction to Operations management.
In week 2, we have covered product design and development; in week 3, we have covered
sales forecasting; in week 4, we have covered plant location and in week 5, we are covering
plant layout or factory layout. Now, we have entered into the factory, we are trying to
do a locational analysis or trying to design and develop a layout of our factory. We are
trying to see that where which facility must be created, must be raised must be erected
so that we are able to meet our overall objective of 4 keywords.
What are these 4 keywords? These 4 keywords are that we must be able to produce the product
with desired quality, desired quantity, at appropriate time, at a competitive cost. So,
these are the 4 parameters; quality, quantity, time and cost. So, we are trying to layout
our factory in such a way that our 4 targets are achieved that we are able to produce a
good quality product in right quantity with reasonable cost, competitive cost and at the
time, it is required in the market. So, the layout also affects the overall productivity
of the organization; within our discussion during this week, we have seen if you remember
that why the layout is important? How do we define a layout? What are the different types
of layout? Then, we have seen in the previous session, what are the most important factors
which govern the type of layout? And we have already now maybe physically moved inside
the premises and we are trying to see that how we can make an optimal layout which will
help us to achieve our objectives of operations management.
We have seen that there are factors which will govern our decisions related to the selection
of a particular type of layout. Today, we are going to cover the material flow patterns
within the layout; how the raw material will enter into the organization or the factory
or the industry and how it will traverse path? And then, how it will come out? How it is
going to influence our layout? Then, we will see what are the advantages of following a
material flow pattern or following a particular type of material flow pattern and what are
the things which will be affected by the improper or maybe a non judicious or maybe a faulty
selection of a material flow patterns. So, all these things, we will try to cover
in today’s session. We may have a horizontal flow pattern or a horizontal material flow
pattern and we may have a vertical material flow pattern. So, we will take examples of
both and try to understand that once we are inside the factory, we have to see that how
the material will move inside the factory or the plant. So that our overall objective
is met and we can ensure a proper flow of the materials proper sequence of operations
on the materials. And finally, we get our desired good quality output and our good quality
output is our product that we are producing. So, let us quickly have a brief introduction
of material Flow Pattern. So, first of all, we need to understand the
what do we mean by Flow Pattern? So, as I have already told our focus is on Material
Flow Pattern. So, material all of you know, how do we define flow pattern let us read
it. “Flow Pattern” means the system to be adopted, for the movement of raw materials,
from beginning and up to the end of manufacturing. So, what is the end of manufacturing that
is the final product has been produced. So, the flow pattern means the system to be
adopted for the movement of raw materials from the entry to the exit, from the maybe
beginning to the ending. So, it is the flow of raw materials within the organization,
within the factory, within the plant. The overall-objective of the ‘Flow Pattern’
is to plan for the economical movement of the raw materials throughout the plant. So,
the word economical is coming into pictures. So, we have to ensure that there is no unnecessary
movement of the material inside the plant. We need to minimize the movement of material;
we need to economize the movement of material inside the plant. Many a time you will see
that you go to a plant and you will if you stay there for some time and observe the movement
of material; even, using common sense you will try to find out that yes, when the plant
was set up. This may have been the most optimal design or the layout of the machines.
But with passage of time we have seen that revision of layout is also done and in the
revised layout, you will see that there is unnecessary movement of materials sometime
which needs to be checked, which needs to be economized, which needs to be optimized
in order to achieve our overall objective of high quality cost effective manufacturing.
So, basically material flow pattern is the pattern or the flow that is being followed
during the manufacturing process specifically for the material. So, we will see that how
the raw material enters into the factory? What sequences of operations are done on the
material? And, how it goes out from the factory? So, that is the basic meaning of the layout
of the material flow pattern. Now, why it is important? Because it affects
the overall productivity of the organization; it affects the material handling cost; it
affects the amount of work in process. Now, work-in-process or WIP is a new term
that has come in our course on operations management. We are using this for the first
time. So, work-in-process is nothing but the materials, the sub assemblies, the subparts,
components that are in the process of production. For example, if you remember in our line type
of layout, we have seen that there are work centers; work centre 1, work centre 2, work
centre 3 and there are 3 components A, B and C that are being manufactured at different
locations or different points and are coming to these 3 work centers are getting assembled
to make a product X. Now these 3 parts will constitute the work-in-process. And finally,
they are getting assembled and are being a part of the final product.
So, the amount of work-in-process is definitely influenced by the type of flow line or flow
pattern that we have chosen within our organization or within our plant layout. Also the flow
pattern will influence the capital and the space tied up by the work-in-process; surely,
it is going to influence the capital and the space tied up. Because sometimes it may so
happen that our work-in-process is getting piled up and we require space to keep that
work-in-process at a particular location and it will definitely affect our flow line and
the flow pattern will also affect means they will affect vice-versa.
For example, we are having huge work-in-process piled up at a particular location; we would
like to bypass that location and try to follow a different flow pattern. On the contrary
suppose, we have selected a particular flow pattern and there is a very slow machine in
between what will happen the work-in-process will pile up at that location. So, the selection
of a flow pattern will also influence the work-in-process or piling of the work-in-process.
On the contrary, if the work-in-process is piled up because of one reason or the other,
it may influence our dynamic change towards the new flow pattern in order to overcome
that situation. So, they are affecting each other. Length
of the total production line is also influenced; we will see that. We have I type of material
flow; we will have U type; we will have S type of material flow that we will try to
understand with the help of diagram, but the flow pattern will certainly influence the
length of our total production line. Now, the flow pattern affects the following. The
rate of the performance and coordination of operations. It also influences the Amount
of physical and mental strain on the operators as well as Supervision and control mechanisms.
So, all points can be explained with the help of certain examples; because suppose, we say
supervision and control mechanism. So, if we have I type of flow pattern, the raw material
is entering from one end and it is getting converted in a linear fashion and at the other
end the product is going out. So the supervisory control maybe not very affective. Because
maybe we may require the length is large; we were required may be 2 or 3 supervisors
to keep a check on may by 8 to 10 operations each. But suppose, we have a U type of pattern,
we can have a centrally located supervisor who can control both the ends of U.
So, the type of flow pattern that we choose, it will affect the type of supervision and
control that we can manage within our organization. Similarly, the amount of physical and mental
strain also is affected by the flow pattern. So, the flow pattern will not only affect
the materials; it will affect the people also, it will affect the procedures also. So, we
have to understand the importance of flow patterns. So, we can see that the rate of
performance and coordination of operation is also affected by the flow pattern.
So with these points, the overall objective of discussing these point is that we must
know, we must be able to highlight; we must be able to understand the importance of the
material flow pattern as; otherwise, usually as students we feel that what how this is
going to affect? It is a simple thing that the raw material is coming; it is following
a particular sequence of operations and it is the material is getting converted into
a final product and it is going out. No, it has got certain importance and the importance
lies in the overall productivity of the organization. Suppose, it is whatever examples we have taken,
we have tried to display or portray a positive picture; we have tried to take positive examples
only. So, let us take if you select of wrong flow pattern, what can happen? Your supervision
is not proper. The quality of work that we are producing is not proper; your work in
process has piled up. So, we can see that there can be so many issues and challenges
if we choose a wrong type of flow pattern. So, it is also important and one thing that
is also covered in earlier discussion also is the effective and efficient use of the
space. Suppose, we have some area or some floor space available with us; we have to
see that how we should locate our machines? What should be the flow pattern of the material;
material flow inside that floor or inside the organization, in that floor space. So,
that the optimal utilization of the space is taking place. Many a time we will see that
a lot of space is being wasted and not utilized properly.
So, the flow patterns, if we address this point in a emphatic manner; we will definitely
be able to save a lot of space or a floor area for our organization. So, just I want
to again reiterate the importance of flow lines and I will read these points again for
you. So, the flow patterns will definitely affect the material handling cost, amount
of work-in-process, capital and space tied up by the work-in-process, length of the total
production line. The rate of the performance and coordination
of operations, amount of physical and mental strain on the operators, supervision and the
control mechanisms. So, all these factors, all these we can say points that has been
written on these 2 slides are being affected directly or indirectly by the selection of
the flow pattern. Now, what are the factors that govern the
flow pattern that we are going to choose? One can be External transport facilities.
Now one example can be a thermal power plant. In thermal power plant, we require coal as
the raw material; coal will burn and then, it will be used as a fuel for the boiler.
Then will produce steam and then, will produce power from that steam.
So, basically we have a raw material that has to reach the plant. Many times you will
see in thermal power plant, there will be a dedicated railway line which will bring
the coal in the wagons. So we have to see that where we have that facility where the
wagons can come, the material can be unloaded from those wagons and then, this can be brought
to the place where it has to be used. So, that distance has to be optimized or minimized
and from there, we see that the raw material is reaching at this point. What can be the
material flow line in order to optimize the overall operations?
For example, there is a very big sheets of material or very bulky raw material which
is which is coming to the organization; where it will be unloaded? Once it is unloaded,
how to ensure that from there it travels the minimum possible path inside the factory.
So, that the overall objective of converting that raw material into the product is achieved,
but the movement of the material is minimized. So, the external transport facilities will
definitely affect we will see with the help of diagrams also that where the material is
getting off loaded is important and will help us to select our flow pattern accordingly.
Then, the number of products to be handled is also important. If you see specifically
in case of assembly type of lines or assembly operations, we will have a straight line or
I type of a line or the flow patterns; because the number of products to be produced is large.
So, we will see that the raw material should come from one end and the final product should
go out from the other end. Suppose, some of you may be wondering that
when the operations have to be done in one line only, why can’t we use a U type of
layout there? Because the sequence remains the same; absolutely true, but the explanation
that comes to my mind is that when we are doing a large scale production, our raw material
will also be huge and the final product that we are making will also be in huge numbers.
So, if we start from one end and follow a particular sequence of operations and the
product also comes out as in the case of U type of flow pattern that we will see that
in the diagram the U type of flow pattern. So, the final product is coming out at the
same end only. Suppose again I am saying this is the U. So, the raw material enters from
one side and it is following a particular sequence of operations and it comes out from
the same side in a horizontal U can be like this.
So, it is entering from a raw material; 1 operation, 2 operation, 3 operation, 5 operation.
Then, sequence of operations and finally, final product. So, here we have huge pile
up of the raw material because the process is continuous, we require to feed the material
continuously and our final product is also coming out continuously.
So, suppose both are in this location or space requirement will be huge. So, we can do one
thing that we can input the raw material from one end and the product can come out from
the other end. So, on both ends we can have the space; on one end, we can have space for
raw material; on the other end, we can have a space for the finished product. So, may
be depending upon the number of products to be handled, we have to choose a type of flow
pattern or the material flow pattern, number of operations on each product is also important
that on each product what is the number total number of operations that we are performing.
Number of units to be processed, I think number of products and units I think this is one
and same thing; number of sub assemblies made up head of assembly line.
So, that is also very important. The number of sub assemblies as we have seen in our example
of a line type of a layout in this week only. That there are work station 1, work station
2, work station 3. Then, there are 3 sub assemblies may be A B and C which are coming to these
work stations in a line. The work stations are arranged in a line and these sub assemblies
are getting assembled with a final product or getting assembled into a final product
which is moving out from the factory layout. So, how many such sub assemblies are there?
What is the size of the sub assemblies? How many parts are there in these sub assemblies?
All these factors will influence our selection of a material flow pattern. So, we will see that what are the number of
sub assemblies? Made up ahead of the assembly line. So, our material flow pattern we are
only talking about final the assembly lines only. So, we have to see that how many sub-assembly
lines coming into the main assembly line. For example, we may take example of a river.
So, our large river is or our main river is our material flow pattern. There can be number
of tributaries that are coming at different points and are getting merged with the main
river. Similarly, our flow pattern is analogous to the main rivers and their tributaries are
analogous to the sub assemblies which are coming and getting merged with the main assembly
line. So, size and shape of the available land; this is the most important parameters
that is coming to my mind because space is the major limitation for setting up any factory.
So, we have always we are hard pressed we are constrained with space. So, we have to
ensure the optimal utilization of space. So, if we have specific area available with us
we will see that which is the most possible or which is the most optimal type of flow
pattern that we must follow, necessary flow between the work areas that also will affect
the flow pattern that we whatever is the necessary flow. Necessary there may be times when we
try to figure out that where is what is unnecessary movement what is necessary moments.
So, once we classify these 2 things we can very easily ensure that we have to plan only
for the necessary flow between the different work areas. So, we have seen that how the
flow pattern is going to affect our overall manufacturing or overall production and how
the, what are the factors that governs the flow patterns. So, these may be theoretical.
From practical point of view, let us see what are the different types of flow pattern? we
have a Horizontal Flow line and we have a Vertical Flow line. So, we will try to make examples of each one
of them these and try to understand that where which type of flow pattern more successful
or more applicable. Horizontal flow lines, you can see there are
so many examples. We can have a I-flow or Line flow. We can have a L-flow, U-flow, S-flow,
O-flow. So, we can see that different types of space
available with us, will force us to choose any one of these flow lines or any one of
these flow pattern. So, let us see what are the maybe salient characteristics. Majorly,
we will see in flow line the raw material will enter into the flow line and then, it
will follow a particular sequence and then, it will come out as a final product. So, overall
may be the picture will remain same, but the physical location of the facilities or machines
or equipment will be in this particular format only or in this particular shape only.
So, I means all of us know what is I? So, ‘I’ maybe 1 straight line. So, the location
of various machines will be in a straight line and the material will move in this line
and during this movement, it will get converted into the final product. So, we may have I-type
of arrangement of machines. We can have a L-shape of arrangement of machines. We can
have a U-shape of arrangement of machines and other facilities. So, this is basically
I, L, U, O are the shapes in which or may be the location in which the various facilities
are arranged within the layout. In previous session, we have seen different
types of layout. For example, in line type of layout, we have to follow a particular
sequence of operations. So, that can be may be one particular layout which is specially,
we can say focused for this type of flow lines because all machines are arranged in a particular
sequence and in a particular shape and the product moves and undergoes the various operations
and finally, comes out as the final or the raw material goes into the different operation
and comes out as a final product. So, we will see how these flow lines look like. So, I-Flow, very simple example on your screen
straight line. It is the simplest form of flow line. In this the materials are fed at
one end and components leave the line at the other end. I-Flow is preferred for building
automobiles in Industries or for developing automobile industries. As I have already taken
an example that I flow line is most suitable for assembly lines. Then, we can have a U-Flow on your screen.
In this both feeding; feeding means the input of raw materials and output that is the final
products. So, in this both feeding or raw materials and output take place at the same
end. Here we can see a U type and there is an arrow which points out at the movement
of the raw materials and this arrow points out at the final product that has been made
or manufactured. So, in comparison to I. This method is easier
for supervision because in between we can have this is the arrangement of machines.
So, we can have supervision in between and we one person can keep a check on both sides.
So, that can be ease of supervision and control mechanism and this type can be adopted in
electric motors, manufacturing of electric motor. This is S-Flow and combination of S-Flows
here. So, if the production line is so long that zigzagging on the plant floor is necessary,
then S-Flow is adopted. Now, this types provides efficient utilization
of space and is compact enough to allow the effective supervision. So, we will see wherever
we are cramped for a space, we will try to go for a S type of layout. But with a condition
that we have to ensure proper circulation space also, the workers or the working personnel
who are working may not feel too cramped in cramped for space.
So, all those parameters have also to be taken into account and then, we arrange our machines
and equipment in S pattern. So, that the material moves in S pattern and finally, gets converted
into the final product. So, we have seen I-type, we have seen U-type, we have seen S-type combination
of S also can be used. Then, O-Flow is another type of flow pattern.
This type is used where processes or operations are performed on a rotary table or a rotary
handling system. So, this can be may be 1 example where again, we want to emphasize
on effective utilization of space, better supervision and control.
So, we can also go for the type of land or the type of floor space available with us;
we can even go for O-type of arrangement of machines. When the component leaves the O-line,
a complete set of process or operations have already been performed. O-Flow can be adopted
by industries manufacturing electrical bulbs or it is not a specific for electric bulbs
only. It can be used for different types or different variety of products, but the arrangement
of the facilities will be in the shape of a O.
Then, may be all these flow lines that we have covered starting from I; then, U and
then, we have seen S; then, we have seen O are coming under the horizontal movement of
the materials only; that we have one floor and on that floor the sequence of machines
is arranged either in the shape of ‘I’ or in the shape of ‘S’ or in the shape
of ‘U’, but then I has, as I have already told you that land is the most precious commodity.
Instead of using x and y coordinates many companies usually go for the z coordinate
also. They do not use only the floor space; they also try to raise the different floors
and make use of the z coordinate also. So, we can have a vertical flow lines also
and different types of vertical flow lines are there. I will read it for you. Processing downward or upward, Centralized
or Decentralized elevation, Unidirectional or Retractional flow, Vertical or inclined
flow, Single or Multi flow. And then, Flow between the different buildings also. Because
last one let me explain, each one can be explained in detail, but this is just to give an idea
that the material flow usually we take it in a horizontal direction also only. But many
times we many Industries, you will have a material flow in the vertical direction across
the various floors of the organization or the factory or the building.
So, the last one like floor flows between buildings. Suppose the company has two buildings.
So, the flow can be either at the top you can have a bridge in which the material can
flow from one building to the other building on the top floor or the material can be at
the ground. So, you bring the material down and at the ground floor only, you are doing
the flow of material from one, one building to the other building may be one explanation
of flow between buildings. So, one example with the help of photographs,
you can see or with the help of picture processing upward or downward. So, these are the different
floor. This is the vertical direction. So, in vertical direction we can have upward or
downward movement, we can have centralized or decentralized elevation; unidirectional
or retractional, we can see. Unidirectional, the material is entering here moving in a
specific direction top floor and then, may be moving downwards and then finally, being
produced here. But here we see the material is entering; then, it is moving here. Again,
moving here. It is gear again retracting again going back to the top and then coming down. So, we can have a unidirectional or retractional
flow. Then, we can have Vertical or Inclined Flow very easily you can see the material
is moving vertically, whereas here it is moving in an inclined fashion. Single or Multi flow
material is entering here, it is being subjected to different operations in a sequence and
then finally, it is getting out and then, there is multi flow also possible. So, we
can see that the material may not flow on horizontal floor only; material may flow in
the vertical directional also across the various floors of the building of an organization.
So, with this we come to the end of today’s session. I think we have tried and we have
been able to understand that within a factory layout, the material takes up a particular
flow line and we have to select the flow of material, we have to arrange our machines
and equipment under the facilities in an specific flow line only in order to ensure the effective
and efficient utilization of the various resources that we are using for converting our raw material
into the final product. So, with this, I conclude the today’s session
and in next session, we will discuss our final aspects related to the topic of factory layout.
Thank you.
