4.

Flow Analysis Techniques

Flow analysis technique is the heart of plant layout and the beginning of the material handling
plan. The flow of a part is the path takes while moving through the plant. Flow analysis not only
considers the path that every part takes through the plant, but it also tries to minimize the 1 )
distance travelled, 2 ) backtracking, 3 ) cross traffic, and 4 ) cost of production.
Flow analysis will assist the manufacturing facilities designer in the selection of the most
effective arrangement of machines, facilities, workstations, and departments.

4.1. Fabrication of Individual Parts

These techniques are mostly used in process layouts. The study of individual parts flow results
in the arrangement of machines and workstations. Route sheet are our primary source of
information. To establish this best arrangement of equipment, by applying the following
techniques:
1. A string diagram.
2. A multi column process chart.
3. A from to chart.
4. A multi product process .

Example -1:

Draw a string, multi column process chart, and a from to chart for the following 5 parts. We
need 2000 units / day of all parts and the parts weight 0.5, 9.0, 0.5, 15.0, and 3.75 pounds
respectively. The cost for forward moving equal to 1, and for backward equal to 2. what is the
efficiency of each method and which one the best ?

Part No. Routing ( Operation Sequences )

1 R-A-B-D-C-F-S
2 R-B-D-C-A-S
3 R-E-F-B-A-C-D-S
4 R-F-A-C-D-S
5 R-C-A-D-S

47
Solution:

For string diagram

R A B C D E F S

Part No. No. of steps travelled

The steps for machines for each
1 9 part is 7. Total = 5 x 7 = 35
2 13
3 17 35
4 17 Efficiency = = 52 Percent
67
5 11
Total 67

The most important relation between pair of two machines through all parts as follows:

R-A 1 A-B 2 B-C - C-D 4 D-E - E-F 1

R-B 1 A-C 4 B-D 2 C-E - D-F - E-S -
R-C 1 A-D 1 B-E - C-F 1 D-S 3
R-D - A-E - B-F 1 C-S - F-S 1
R-E 1 A-F 1 B-S -
R-F 1 A-S 1
R-S -

48
 R E F B A C D S

The most important relation between pair of two machines through all parts as follows:

Part No. No. of steps travelled

The steps for machines for each
1 17 part is 7. Total = 5 x 7 = 35
2 11
3 7 35
4 7 Efficiency = = 69 Percent
51
5 9
Total 51

For multi - column process chart

Using the same routing used in the string diagram for the five parts as shown below:

49
 Multi - Column Process Chart

Parts Number
1 2 3 4 5

S
Total
Steps 9 13 17 17 11
67

7 7 7 7 7 35

35
Efficiency = = 52%
67
This is the same efficiency we established in a string diagram. Lets try to improve it again.

The most important relation between pair of two machines through all parts as follows:

R-A 1 A-B 2 B-C - C-D 4 D-E - E-F 1

R-B 1 A-C 4 B-D 2 C-E - D-F - E-S -
R-C 1 A-D 1 B-E - C-F 1 D-S 3
R-D - A-E - B-F 1 C-S - F-S 1
R-E 1 A-F 1 B-S -
R-F 1 A-S 1
R-S -

50
 Multi - Column Process Chart

Parts Number
1 2 3 4 5

S
Total
Steps 17 11 7 7 9
51

7 7 7 7 7 35

35
Efficiency = = 69 %
51

For from to chart

The from to chart is the most exact techniques of the three.

Part No. Quantity/day Weight in Toatl Relative
Ppounds Weight Importance

1 2000 0.5 1000 1.o

2 2000 9.0 18000 18.0
3 2000 0.5 1000 1.0
4 2000 15.0 30000 30
5 2000 3.75 7500 7.5

51
We can see that, part 4 is most important than part 1 by 30 times.

P.P = Relative importance x Distance x Cost

The distance matrix shown below:

Forward
Distance Matrix Cost Matrix

1 2 3 4 1 2 3 4

1 1 2 3 1 1 1 1

2 1 2 1 2 2 1 1
2
3 2 1 1 3 2 1

4 3 2 1 4 2 2 2

Backtracking

TO
R A B C D E F S T P.P

1 18 7.5 1 30 57.5
R
1 36 22.5 5 180 211.2

1 31 7.5 18 57.5
A
1 31*2*1=62 22.5 108 193.5

Distance

1 19 20
B
2 38 40

25.5 31 1 57.5
C
25.5*2*2=102 31 3 136

FROM
19 38.5 57.5
D
38 115.5 153.5

Cost 1 1
E
1 1

30 1 1 32
F
300 8 1 309

----
S
----

After improving the operation sequences.

52
 TO
R E F B A C D S T P.P

1 30 18 1 7.5 57.5
R
1 60 54 4 37.5 156.5

Distance
1 1
E
1 1

1 30 1 32
F
1 30*2*1=60 5 66

25.5 1 1+18=19 20
B
1 57 58

FROM
1 1+30=31 7.5 18 57.5
A
2 31 15 18*3*1=54 102

Cost 1 18+7.5=25.5 31 57.5

C
6 51 31 88

1+30+7.5=
19 38.5 57.5
D
38 38.5 76.5

----
S
----

Example 2:

Given the spatial schematic below, evaluate the flow path lengths for the following components.
A B C D , A B A C D.

A

50'
D

50'
25'

C
B 50' 75'

Solution:

Flow path A B C B = ( 50 + 50 ) + 50 + ( 75 + 25 ) = 250 feet

53
Flow path: A - B - A - C - D = ( 50' + 50' ) + ( 50' + 50 ) + [( 50' + 50' ) + 50' ] + ( 75' + 25' ) = 450 feet

Backtrack Penalty

Example -3:

A firm produces three components. Component 1 and 2 have the same size. Component 3 is
almost twice as large. Therefore, moving two units of components 1 or 2 is equivalent to moving
one unit of component 3. Show material flows between machines on a from-to chart.

Component Production Routing

quantity / day

1 30 A-C-B-D-E
2 12 A-B-D-E
3 7 A-C-D-B-E

Solution:
A-B 1 B-C -- C-D 1 D-E 2
A-C 2 B-D 2 C-E --
A-D -- B-E 1
A-E --
A C B D E
1+3 2
A 12
30+2(7)=44

1 3
C 30 7*2=14

1+2
30+12=42
B

3 1+2

D 7*2=14 30+12=42

54
4.2. Multi Product Process

A ) Data Requirements

1. Routing sheet and process chars.

2. Product Mix., volume of production and unit load.
3. Departments area.

B ) Solution steps:

1. Form from to load ( move / flow ) matrix [ L ]

2. Draw flow diagram network.
3. Rearrange flow so that movement is reduced.
4. Draw department dimension considering square or rectangular shape. Calculate distance
between department centers ( linear X+ Y ), or Euclidian ( X2 + Y2 )0.5.

Example -4:

An industrial company produces five parts according the sequence and unit loads given in routing
sheet. Develop the layout.

Part Sequnce Load / Period

Dept. 1 2 3 4 5 6 7 8 9 10
A 1,4,7,9,10 50
B 1,2,4,5,6,8,9,10 100 Area
C 1,2,4,5,6,9,10 200 ft2 450 300 150 300 400 250 300 150 300 600
D 1,2,5,6,7,9,10 150
E 1,3,2,4,7,10 50

Solution:

55
 1- [ L ] From - To Chart
1 2 3 4 5 6 7 8 9 10

1 450 50 50

2 350 150

3 50

300 100
4

450
5

150 100 200

6

7 200 50

8 100

50
9

10

50
50
450 350 100 200
1
2 4 7 9 10

50 150 300 150

50 200 100

450 100
3 5 6 8
Initial solution

56
Final Solution

50
3 1
10
50 450 50 50
500
350 100 200
2 4 7 9
300 200
150 150 100
450
5 6 8
100

Actual Layout

3 1 10

7 9
2 4

6 8
5

57
 Assignments # 4

Q.1:
XYZ Inc. has a facility with six departments A, B, C, D, E, and F. A summary of the processing
sequence for the 6 parts, weekly production forecasts and the parts weight. The cost for forward
moving equal to 1, and for backward equal to 2. The data given below:

Parts Processing Sequence Weekly prod. Weight parts

1 A-B-C-D-E-F 1200 1.50
2 A-C-E-F 2000 0.50
3 A-B-D-F 1000 3.50
4 A-B-E-C-F 800 12.00
5 A-C-B-E-F 1350 6.00
6 A-B-D-C-E-F 1450 4.00

Develop a String diagram, Multi Column process chart, and From to chart. What is the
efficiency of each method and which one the best ?

Q.2:

A steel manufacturing company makes seven different types of products. There are eight equal
sized department involved. The cost for forward moving equal to 1, and for backward equal to 2.
Given the following data below:

Product Processing Sequence Weekly Prod. Unit Weight

1 A-B-C-D-F-G 500 1.20
2 A-B-E-C-G 350 2.40
58
 3 A-C-B-E-F-G 150 4.00
4 A-D-C-F-E-G 200 3.50
5 A-F-C-D-G 150 12.00
6 A-B-C-D-E-G 440 3.50
7 A-C-E-F-D-G 280 6.50

Develop a String diagram, Multi Column process chart, and From to chart. What is the
efficiency of each method and which one the best ?

Q.3:

Given the spatial schematic below, evaluate the flow path lengths for the following components.

A B C D E F

100' 75' 75' 25' 25'

a. Component 1 routing A B C D E F
b. Component 2 routing A C B D E F
c. Component 3 routing A F E D C B A F
d. Component 4 routing A C E B D F

Q.4:
A firm produces three components. Component 1 and 2 have the same size. Component 3 is
almost twice as large. Therefore, moving one haft units of components 1 or 2 is equivalent to
moving one unit of component 3. Show material flows between machines on a from-to chart.

Component Production Routing

quantity / day

1 30 A-C-B-D-E
2 12 A-B-D-E
3 7 A-C-D-B-E

Q.5:

An industrial company produces Six parts according the sequence and unit loads given in routing
sheet. Develop the layout.

Product Processing Sequence Load / Period

A 1,4,7,9,10 60
B 1,2,4,5,6,7,9,10 100
C 1,2,4,5,6,8,9,10 200
D 1,2,4,5,6,9,10 150
59
 E 1,3,2,4,7,10 50
F 1,2,4,3,5,6,9,10 100

The area of departments as given in example 4.

60