Production Flow Analysis: A Foundation

for Design of a Lean Facility Layout

Symptoms of Inefficient Material

Flows in a Facility

Large travel distances in the material flow diagram

Perceived shortage of floor-space for facility expansion
High WIP inventory levels
Large inter-machine transfer batch sizes
High levels of finished product inventories
Bottleneck resources with large queues
Large cycle times for order fulfillment
Significant queuing and material handling delays
Significant forklift truck activity
Poor order tracking capability
Highly unpatterned material flow network
Absence of a network of material handling aisles
Inefficient communications between workcenters
Low machine and labor utilization
Frequent machine setups
Absence of pull scheduling based on resource constraints
Inflexibility to handle demand and/or part mix changes

Causes of Poor Material Flows in a Facility

Building architecture
Locations of manufacturing departments
Locations of support services and utilities
Design of the network of material handling aisles
Locations of input/output points of departments
Shortage of space for facility expansion
Process plans for making parts and products
Variety of routings in the part mix
Current manufacturing technology
Current material handling equipment in use
Current material handling scheduling policies
Choice of subcontracted operations and/or parts

Benefits of Using PFA for Facility Layout

Verification and updating of operational and planning documents

Verification and updating of current equipment inventory
Review and improvement of business and manufacturing processes
Redesign of product designs
Redesign of process plans
Strategic reallocation of equipment between departments
Strategic duplication of equipment between departments
Strategic consolidation of departments
Strategic investment in flexible multi-function equipment
Planning for flexibility - machine, process, routing, volume, etc.
Implementation of capacity-constrained scheduling techniques
Implementation of efficient machine loading rules
Implementation of efficient job sequencing rules
Implementation of setup reduction practices
Revision of the product routings to eliminate redundant variety
Revision of the product routings to eliminate "outlier" routings

Reasons for the Project at Company X

Machines not located in close proximity
Machines not arranged according to the process flow
Backtracking in the process flow
A new layout would save floorspace
Lack of streamlined material and operator flows
The area and layout of several machine footprints are not optimized
WIP quantities at different machines differ significantly
Material is moved in large batches between machines
Significant delays in order throughput
Quality problems due to absence of feedback* between machines
*

due to large distances of separation

Reasons for the Project at Company X (contd)

No production planning, finite capacity scheduling system or
shopfloor control systems to track and progress orders
Lack of prompt communications between the shopfloor and the
production planner
Production lot sizes are not based on any systematically planned
master production schedule
Difficulty in synchronizing production with the supply schedule for
forgings

Design For Flow Principles for Effective

Layout Design
Maximize:

Directed flow
One piece flow
Ergonomics of material handling in every workcell
Visual scheduling and material flow control
Flexibility to accommodate variations in product mix and /or volume

Minimize:

Backtracking
Transfer batches
Travel distance in every workcell
Travel distances between consecutive workcells
WIP storage space between consecutive workcells*
* design of a standard storage cart (Kanbin)

Design of a Standard Storage Cart (Kanbin)

Original Design:
E x p a n d e d c a p a c it y = 8 c r a n k s h a f t s

Proposed Design:
O r ig in a l C a p a c it y = 4 c r a n k s h a f t s

d
d

W a s te d

.5 d

.5 d

v o lu m e
.5 d

8d

d = d ia m e te r o f th e c r a n k s h a f t

5 .5 d

Routing for 6-cylinder Products

Lycoming 6 Cylinder
Op#

Operation
Description

10
11
12
13
14
20
30
50
70
80
100

Rough Turn Flange

Rough Turn B3, B4 & B5
Rough Turn Flange End, B1, B2 & B3
Mill Locating Pads
Rough Mill Pins
Turn B3, B4 & B5
Turn Flange End, B1/B2, B3 & Profile C1 & C9
Cheek & Mill Pins
Rough Drill Front End
Gundrill Main Bearing Lightening Hole
Drill Pin Lightening Holes

110

Stress Relieve,Check Runout & Straighten

115
132
134
135
140

180
190
200

Wheel-a-brate Crankshaft
Face & Re-Center Small End
Spot Grind B1 & B2
Finish Bore Front End
Turn Flange, Boss, Seal, Oil Slinger, B1/B2
Ream Rear Plug Hole, Drill & Ream Manufacturing Hole
Drill Oil Holes
Bump Grind Pin Cheeks
Mill Sides of C'weight Supports
Mill Flats (For Part No.609 only)
Profile C'weight Supports & Drill, Ream, C'bore Cross Tube Hole
Deburr Crankshaft
Semi-Finish Grind B1/B2
Finish Grind B3, B4 & B5
Finish Grind Pins

210

Drill & Rough Ream Support Holes

220

Grind Counterweight Supports

230

Magnetic Particle Inspection, Deburr & Polish

235

Dynamically Balance

150
160
165
170

M/C#
380
568
569
768
757
568
569
757
777
735
745
761
764
758
147
567
724
567
763
843
748
791/793
379
379
738
N/A
756
765
734
769/770
795
759
776
736
1027
751
161
746
940
521
590
N/A

M/C
Description
Engine Lathe
Mori Seiki SL-25
Mori Seiki SL-25
Cincinnati Mill
GFM Pin Mill
Mori Seiki SL-25
Mori Seiki SL-25
GFM Pin Mill
Turret Lathe
Gun Drill
2G&L
Drill Presses
Oven
Dennison Hydrl. Press
Wheelabrator
Mori Seiki TL-40
Landis Grinder
Mori Seiki TL-40
Cincinnati Lathe
Radial Arm Drill
Oil Hole Drill
Landis Grinder
Cincinnati Mill
Cincinnati Mill
Okuma & Howa
Deburr Bench/Table
Landis Grinder
Landis Grinder
Manual Pin Grinder
Auto Landis Grinders
Cincinnati Drill Press
G & L Drill Press
Mattison Surface
Grinders
Varsol Wash Tank
Washer
Maggie
Deburr Bench
Polish Bench
Balancer
Snag Grinder
Hand Sander, Bench/Table

Routing for 4-cylinder Products

Op#

Operation
Description

10
20
30
40
50
70
80

Rough Turn Flange

Turn B3/B4 and Crankcase Clearance
Turn Flange End & B1/B2
Mill Locating Pads
Cheek & Mill Pins
Rough Drill Front End
Gundrill Main Bearing Lightening Hole

100

Drill Pin Lightening Holes

110

Stress Relieve,Check Runout & Straighten

115
132
134
135
140

Wheelabrator Crankshaft
Face & Re-Center Small End
Spot Grind B1 & B2
Finish Bore Front End
Turn Flange, Boss, Seal, Oil Slinger & B1/B2
Ream Rear Plug Hole, Drill & Ream Manufacturing Hole
Drill Oil Holes

150
160
165
170
180
190
200
210
220

Bump Grind Pin Cheeks

Mill Flats
Profile C'weight Supports & Drill, Ream, C'bore Cross Tube Hole
Deburr Crankshaft
Semi-Finish Grind B1/B2
Finish Grind B3 & B4
Finish Grind Pins
Drill & Rough Ream Support Holes
(For Part# 203,205,208,209 & 211)
Grind Counterweight Supports
(For Part# 203,205,208,209 & 211)

230

Magnetic Particle Inspection, Deburr & Polish

235

Dynamically Balance

240

Preliminary Inspection Prior To Nitride

M/C#
380
568
569
768
1025
777
777
735
741
754
764
758
147
567
724
567
763
843
748
778
791/793
379
738
w/738&772
756
765
734
769/770
795
759
776
736
1027
751
161
746
940
521
590
N/A

M/C
Description
Engine Lathe
Mori Seiki SL-25
Mori Seiki SL-25
Cincinnati Mill
GFM Pin Mill
Turret Lathe
Turret Lathe
Gun Drill
Carlton Drill Press
G & L Drill Press
Oven
Dennison Hydrl. Press
Wheelabrator
Mori Seiki TL-40
Landis Grinder
Mori Seiki TL-40
Cincinnati Lathe
Radial Arm Drill
Oil Hole Drill
Bridgeport
Landis Grinder
Cincinnati Mill
Okuma & Howa
Deburr Bench/Table
Landis Grinder
Landis Grinder
Manual Pin Grinder
Auto Landis Grinders
Cincinnati Drill Press
G & L Drill Press
Mattison Surface
Grinders
Varsol Wash Tank
Washer
Maggie
Deburr Bench
Polish Bench
Balancer
Snag Grinder
Hand Sander, Bench/Table
Inspection Area

Comparison of Routings for 6-cylinder and

4-cylinder Products
Lycoming 6 Cylinder
Op#
10
11
12
13
14
20
30

380
568
569
768
757
568
569

M/C
Description
Engine Lathe
Mori Seiki SL-25
Mori Seiki SL-25
Cincinnati Mill
GFM Pin Mill
Mori Seiki SL-25
Mori Seiki SL-25

50
70
80

757
777
735

GFM Pin Mill

Turret Lathe
Gun Drill

100

745
761
764
758
147
567
724
567
763
843
748
791/793
379
379
738
N/A
756
765
734
769/770
795
759
776
736
1027
751
161
746
940
521
590
N/A

110
115
132
134
135
140
150
160
165
170
180
190
200
210
220

230

235
240

M/C#

Lycoming 4 Cylinder
Operation
Description

Op#

Rough Turn Flange

Rough Turn B3, B4 & B5
Rough Turn Flange End, B1, B2 & B3
Mill Locating Pads
Rough Mill Pins
Turn B3, B4 & B5
Turn Flange End, B1/B2, B3 & Profile C1 & C9
Mill Locating Pads
Cheek & Mill Pins
Rough Drill Front End
Gundrill Main Bearing Lightening Hole

10

380

M/C
Description
Engine Lathe

20
30
40
50
70
80

2G&L
Drill Presses
Oven
Dennison Hydrl. Press
Wheelabrator
Mori Seiki TL-40
Landis Grinder
Mori Seiki TL-40
Cincinnati Lathe
Radial Arm Drill
Oil Hole Drill

Drill Pin Lightening Holes

100

Stress Relieve,Check Runout & Straighten

110

Wheel-a-brate Crankshaft
Face & Re-Center Small End
Spot Grind B1 & B2
Finish Bore Front End
Turn Flange, Boss, Seal, Oil Slinger, B1/B2
Ream Rear Plug Hole, Drill & Ream Manufacturing Hole
Drill Oil Holes

115
132
134
135
140

Landis Grinder
Cincinnati Mill
Cincinnati Mill
Okuma & Howa
Deburr Bench/Table
Landis Grinder
Landis Grinder
Manual Pin Grinder
Auto Landis Grinders
Cincinnati Drill Press
G & L Drill Press
Mattison Surface
Grinders
Varsol Wash Tank
Washer
Maggie
Deburr Bench
Polish Bench
Balancer
Snag Grinder
Hand Sander, Bench/Table
Inspection Area

Bump Grind Pin Cheeks

Mill Sides of C'weight Supports
Mill Flats (For Part No.609 only)
Profile C'weight Supports & Drill, Ream, C'bore Cross Tube Hole
Deburr Crankshaft
Semi-Finish Grind B1/B2
Finish Grind B3, B4 & B5
Finish Grind Pins

160
165

568
569
768
1025
777
777
735
741
754
764
758
147
567
724
567
763
843
748
778
791/793
379

Mori Seiki SL-25

Mori Seiki SL-25
Cincinnati Mill
GFM Pin Mill
Turret Lathe
Turret Lathe
Gun Drill
Carlton Drill Press
G & L Drill Press
Oven
Dennison Hydrl. Press
Wheelabrator
Mori Seiki TL-40
Landis Grinder
Mori Seiki TL-40
Cincinnati Lathe
Radial Arm Drill
Oil Hole Drill
Bridgeport
Landis Grinder
Cincinnati Mill

Drill & Rough Ream Support Holes

210

Grind Counterweight Supports

220

Magnetic Particle Inspection, Deburr & Polish

230

Dynamically Balance

235

738
w/738&772
756
765
734
769/770
795
759
776
736
1027
751
161
746
940
521
590
N/A

Preliminary Inspection Prior To Nitride

240

Okuma & Howa

Deburr Bench/Table
Landis Grinder
Landis Grinder
Manual Pin Grinder
Auto Landis Grinders
Cincinnati Drill Press
G & L Drill Press
Mattison Surface
Grinders
Varsol Wash Tank
Washer
Maggie
Deburr Bench
Polish Bench
Balancer
Snag Grinder
Hand Sander, Bench/Table
Inspection Area

150

170
180
190
200

M/C#

Initial Layout of Company X Shopfloor

DO CK

5th Aisle

4th Aisle

1 s t A is le

1st B ay

2 n d A is le

B o r r in g e r

6th Aisle

3 rd B a y

5 th B a y
3 r d A is le

4 th B a y

6 th B a y

2nd Bay

Flow Diagram for 6-cylinder Products

START
FINISH

Flow Diagram for 4-cylinder Products

START
FINISH

Preliminary Layouts Presented to Company X

Layout #1

O ven
O p#110

Dock

R M

F G

M /C # 5 6 7
O p# 132

B o r r in g e r

M /C
147

Company X feedback on Layout #1*:

Allows direct line of sight between the Oven and the Wheelabrator
Does not require relocation of the Borringer
Keeps the Oven close to the dock In the summer, heat can escape
easily through the dock
* This layout was chosen by the company

Preliminary Layouts Presented to Company X

Layout #2

B re a k R o o m

FG

Dock

FG

M /C # 5 6 7
O p# 132

O ven
O p#110

O ven
O p#110

R M

M /C
147

Company X feedback on Layout #2:

Oven cannot be moved into the position shown because the
Borringer cannot be relocated
Prevents direct line of sight between the Oven and the
Wheelabrator

Preliminary Layouts Presented to Company X

Layout #3

O p # 1 0 0

Dock

R M

M /C # 5 6 7
O p # 1 3 2

B o r r in g e r

O ve n
O p # 1 1 0

M /C
1 4 7

Company X feedback on Layout #3:

Oven cannot be moved into this position

F G

Flow Diagram showing Lean Flow in an

Initial Layout that was Proposed

Flow of both 6-cylinder

and 4-cylinder products
Flow of 6-cylinder
products only
Flow of 4-cylinder
products only

Constraints on Layout Design

Borringer cannot be relocated.
Final Inspection Area cannot be located near the Dock because winter cold
would affect parts and gauges.
M/Cs 757 and 1025 need 17' clearance on one side where their chip
conveyors (17' in length) may need to be pulled out for machine
maintenance.
M/C 567 (Mori Seiki) needs 13' clearance on one side where its chip
conveyor (13' in length) may need to be pulled out for machine
maintenance.
All M/Cs need to be accessed from at least one aisle for machine
maintenance.
An inspection area (10' by 20') must be located centrally in the flowline.
The aisles could be used to accommodate large machines projecting out of
a bay.
The 5th bay should be kept clear to implement new product lines. (See
Initial Layout of Company X Shopfloor shown earlier)

Constraints on Layout Design (Contd)

Final Inspection Area constraints:
M/Cs 776 and 736 (Grinders) and M/C
590 (Snag Grinder) create too much dust that could corrupt the Maggie.
Therefore Maggie cannot be located adjacent to the Grinders.
Creates
Dust

776

736

Needs
to be
Dust
Free

Wet

1027

751

161
Maggie

Creates
Dust

746

940

Creates
Dust

521

590

Hand Sander

Balancer

F in a l In s p e c t io n
Needs to be Protected
from Cold and Dust

* M/Cs in the Finish

Grinding area were
removed by Lycoming
during the project period.

M/Cs #510 and #738 (Okuma & Howa) were taken out of the machining line.
M/C #109 (Bridgeport) was replaced by M/C #778.
M/Cs #795 ( Cincinnati Drill Press) and #759 (G&L Drill Press) were to be
replaced by a new machine.

Final Layout based on Lean Flow

N
Incoming Cart
Operators Standing Point

Dock

Detailed Layout of Workcells

(M/Cs #380, #568 and #569)
N

Note: All measurements are in feet.

Detailed Layout of Workcells

(M/C #768 and GFMs)
N
Spacing Bench can be easily
shared by two GFM operators

*The constraint of 17' clearance is satisfied for both GFMs in this layout.
Note: All measurements are in feet.

Detailed Layout of Workcells

(M/Cs #777 and #735)
Leave 5' between the two M/Cs to minimize the operators
travel distance

Note: All measurements are in feet.

Detailed Layout of Workcells

(M/Cs #567 and #724)
N
AISLE

AISLE
Note: All measurements are in feet.

Detailed Layout of Workcells

(M/Cs #763 and #843)
N

AISLE

AISLE

Note: All measurements are in feet.

Detailed Layout of Workcells

(From M/C #756)
N

Locate the vending

machines in this way in
order not to block the line of
sight between consecutive
workcells

Incoming Kanbin Cart

Operators Standing Point

Note: All measurements are in feet.

Detailed Layout of Workcells

(Operation #180 to Operation #235)
N

A IS L E

L e a v e 6 ' f o r s id e w a y tr a v e r s e

A IS L E

New
M a c h in e

V e n d in g M a c h in e s

A IS L E

S p a c in g B e n c h is lo c a t e d a t e q u a l
d is t a n c e f r o m t h e o p e r a t o r s w o r k in g o n
# 7 3 4 , # 7 6 9 /7 7 0 a n d # 7 7 6 /7 3 6

Detailed Layout of Workcells

(Final Inspection Area)
N
A IS L E

C u p b o a rd

V e n d in g M a c h in e

A IS L E
L y c o m in g
In s p e c tio n
A re a

T w o file
c a b in e ts
G a u g in g T a b le

Tank

I n s p e c t io n
T a b le s
H a rd n e s s
T e s te r

R e w o rk
T a b le
S ta g in g
T a b le

Box

A IS L E

In c o m in g K a n b in

R o t a te t h is L a y o u t T a b le 9 0 d e g r e e s t o
s m o o t h o p e r a t o r 's m o v e m e n t

Note: All measurements are in feet.

Key Benefits of the Lean Layout

Pure flowline layout
Smooth workflow within every workcell
Space was freed to accommodate a new product line
Standardization of containers for WIP storage and transfer (Kanbin)

Decrease in transfer batch sizes

Reduction in floorspace due to proximity of cells

Optimization of several machine footprints

Improved communications between consecutive operations
Layout designed for and with full cooperation of Company X
operators, supervisors and managers

Conclusion
..Thank you for the excellent work that you and your students did on
the project. While it was a learning experience for us, Im sure your
students gained much more by seeing the classroom applied to the shop
floor. It is rare to find an academician that is as comfortable on the shop
floor as you are. This attribute helps not only the client using the service,
but also the student, as it shows the student how it should be done in the
real world.
I believe the partnership between a public university and private industry
is extremely important as it enables the businesses in the State of Ohio to
enjoy the fruits of a great institution of higher learning. The way to make
manufacturing in Ohio competitive into the future is to do just what we
did, apply academic principles to the practical world on the shop floor.
We are on our way to becoming more profitable and competitive thanks to
the work your team did at Company X...
Chief Financial Officer (Company X)

Schedule of Project Activities

Description of Activity
Proposal Discussion and Contract Finalization
Data Collection and Verification
Generation of Flow Diagrams
Preliminary Layout Development
Preliminary Layout Verification
Measurements and Layout Walk-throughs
Detailed Workcell Layout Design
Relocation of Machines
Final Report and Presentation

JANUARY
FEBRUARY
MARCH
APRIL
MAY
JUNE
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