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Facility Layout and Design Concepts
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Flexible manufacturing system (FMS)
Combines high flexibility with high efficiency by using automated machines and a central control system, expensive but can reduce setup times and work in process.
Cross-docking
Products are received through an inbound dock and immediately transferred across the dock to the outbound transportation dock, which reduces storage and handling costs but requires tight scheduling.
Fixed-position layout
Used when products are too large or heavy to move, which minimizes product movement but can complicate resource planning and scheduling.
Material handling
Involves the movement of materials within a facility, which impacts efficiency, product flow, and worker safety, and should be optimized to reduce costs.
Process-oriented layout
Facilitates the processing of a variety of products or services with intermittent workflow, improving flexibility but potentially increasing transportation costs.
Cellular layout
Groups different machines into cells that process a family of parts with similar shapes or processing requirements, reducing lead time and work in process.
Just-In-Time (JIT) layout
Reduces waste by keeping inventory levels low and uses small, decentralised workstations, which requires robust planning and is vulnerable to disruptions.
Ergonomics
Considers the interaction between people and systems in the work environment, improving safety, comfort, and productivity but requiring careful design and investment.
Product-oriented layout
Supports the production of a few standardized products at high volumes, which enhances efficiency but reduces flexibility.
SMED (Single-Minute Exchange of Dies)
Aims to reduce equipment setup times to less than 10 minutes, which increases operational efficiency and flexibility but requires initial investment and training.
Throughput
The rate at which a facility produces goods relative to the capacity, affecting profitability and efficiency, and can be used to measure performance.
Six Sigma
A set of techniques and tools for process improvement, aiming at reducing variability and defects to enhance quality and efficiency, necessitating cultural change and ongoing training.
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