An arranges processes according to the sequence of steps by which the product is manufactured

Typical plant layout, done through CAD. Note that layout for a production system reflects a conceived organisation of resources to achieve a certain goal, besides satisfying certain space constraints.

In manufacturing engineering, process layout is a design for the floor plan of a plant which aims to improve efficiency by arranging equipment according to its function.[1] The production line should ideally be designed to eliminate waste in material flows, inventory handling and management.[2] In process layout, the work stations and machinery are not arranged according to a particular production sequence. Instead, there is an assembly of similar operations or similar machinery in each department (for example, a drill department, a paint department, etc.)

It is also known as function layout. In this layout machining operation are performed in group together and not arranged according to any sequence.

Main advantages[edit]

1. Provide visual control of activities
2. Use space efficiently
3. Use labour efficiently
4. Eliminate bottlenecks
5. Facilitate communication and interaction between workers and supervisors
6. It is environmental friendly

Criticism[edit]

A common criticism of this layout is that the work can be monotonous for staff, especially if they are involved only in one stage of the process. This criticism can however be eliminated if the staff are rotated to different departments (involving different processes) thus developing a multi-skilled body of staff.

See also[edit]

• Product layout

References[edit]

1. ^ Mikell P. Groover (2007). Work Systems: The Methods, Measurement & Management of Work. Prentice Hall. ISBN 978-0-13-140650-6
2. ^ Shigeo Shingo(1985). "A revolution in Manufacturing: The SMED System". Productivity Press. ISBN 0-915299-03-8

Further reading[edit]

• S.N. Chary (2006). Production and Operations Management. McGraw Hill. ISBN 978-0-07-058355-9
• S. Moran (2016). Process Plant Layout. Elsevier. ISBN 978-0128033555

Quality Glossary Definition: Flowchart

Also called: process flowchart, process flow diagram

Variations: macro flowchart, top-down flowchart, detailed flowchart (also called process map, micro map, service map, or symbolic flowchart), deployment flowchart (also called down-across or cross-functional flowchart), several-leveled flowchart

A flowchart is a picture of the separate steps of a process in sequential order. It is a generic tool that can be adapted for a wide variety of purposes, and can be used to describe various processes, such as a manufacturing process, an administrative or service process, or a project plan. It's a common process analysis tool and one of the seven basic quality tools.

Elements that may be included in a flowchart are a sequence of actions, materials or services entering or leaving the process (inputs and outputs), decisions that must be made, people who become involved, time involved at each step, and/or process measurements.

When to Use a Flowchart

• To develop understanding of how a process is done
• To study a process for improvement
• To communicate to others how a process is done
• When better communication is needed between people involved with the same process
• To document a process
• When planning a project

Flowchart Basic Procedure

Materials needed: Sticky notes or cards, a large piece of flipchart paper or newsprint, and marking pens.

1. Define the process to be diagrammed. Write its title at the top of the work surface.
2. Discuss and decide on the boundaries of your process: Where or when does the process start? Where or when does it end? Discuss and decide on the level of detail to be included in the diagram.
3. Brainstorm the activities that take place. Write each on a card or sticky note.
4. Arrange the activities in proper sequence.
5. When all activities are included and everyone agrees that the sequence is correct, draw arrows to show the flow of the process.
6. Review the flowchart with others involved in the process (workers, supervisors, suppliers, customers) to see if they agree that the process is drawn accurately.

Flowchart Considerations

• Don’t worry about drawing the flowchart the "right way." Ultimately, the right way is the way that helps those involved understand the process.
• Identify and involve in the flowcharting process all key people involved with the process. This includes suppliers, customers, and supervisors. Involve them in the actual flowcharting sessions by interviewing them before the sessions and/or by showing them the developing flowchart between work sessions and obtaining their feedback.
• Do not assign a "technical expert" to draw the flowchart. People who actually perform the process should do it.

Flowchart Examples

1. High-Level Flowchart for an Order-Filling Process

2. Detailed Flowchart

Commonly Used Symbols in Detailed Flowcharts

Develop a Flowchart

Use the flowchart template (Excel) to create a graphical representation of the steps in a process to better understand it and reveal opportunities for improvement.

Flowchart resources

You can also search articles, case studies, and publications for flowchart resources.

Books

Mapping Work Processes

The Quality Toolbox

Articles

Flowcharting With Excel (Quality Management Journal) A method is presented for teaching flowcharting using Microsoft Excel. While the focus is on the academic environment, the method is relevant for corporate trainers and novice users. Flowcharting is treated as a graphical language with its own vocabulary and syntax. Suggestions and precautions enhance the legibility and communicative power of the tool. In addition, extensions are offered to allow customization of individual process maps to specific user needs.

Back To Basics: Flowcharts For A Smooth Ride (Quality Progress) A flowchart might be one of the more basic of the seven tools of quality, but it is a very useful one. Flowcharts, also known as process maps, help paint a picture of a process to sort out steps and missteps.

Courses

ASQ Quality Tools - Flowchart

Adapted from The Quality Toolbox, Second Edition, ASQ Quality Press.

Which layout format groups machines to work on products that have similar processing requirements?

What specifies the order in which a firm will make product components?

Which are characteristics of a continuous process line?

Which layout moves product from workstation to workstation at a controlled rate?