Flow Analysis

Techniques

Dr. Saeed Tasouji Hassanpour

Objectives

1. Understand why analyzing the movement of materials is important.

2. Learn different tools to analyze material flow.
3. Calculate how efficiently materials move using a "from-to" chart.
 What is Flow Analysis?
• Flow analysis is all about understanding the path materials take as they
move through a factory.
• It is the starting point for designing how materials will be handled and
organized in the plant.

o Minimizing how far parts travel (distance),

o Reducing backtracking,
o Avoiding cross-traffic,
o Lowering production costs.
Why it is important?
•When designing a factory layout, flow analysis helps arrange
machines, workstations, and other parts of the facility effectively.

•Improving material flow can directly boost profitability.

•Flow analysis is like organizing similar tasks together so that parts

follow a consistent path, reducing complexity and automating
movement where possible.
Different Layouts
Product-Oriented Layout:
Designed around the product's flow, making things leaner and more efficient.

• Assembly lines or cells where parts move smoothly through production.

• Less work-in-process inventory, faster problem-solving, and easier to
standardize work.

Process-Oriented Layout: Focuses on grouping similar equipment.

• Suitable when there are many different parts or products with varied
steps.
Fig 5-1a:
• Machines are grouped by function
rather than by the flow of a single
product
• The parts may need to move back
and forth between different
machines,
• A complex flow with potential for
backtracking and cross-traffic
• The path is not linear, and parts
can travel in multiple directions
depending on the operation
required

Fig 5-1b:
• Machines are arranged based on
the sequence of operations needed
for the product,
• A more streamlined, linear flow.
• Parts move in a straight line,
reducing unnecessary movement
and making the flow more efficient.
Key Differences Between Layouts
1
• Material flow is smoother and travels shorter distances in
product-oriented plans.

2
• Less confusion and more streamlined operations.

• Product-oriented setups may require simpler, dedicated

machines instead of expensive, flexible ones.
 Flow Analysis Tools
String Diagrams

Multicolumn Process Charts

From-To Charts

Process Charts
Part No. 1: The sequence is R → A → B → D → C → F → S.
Part No. 2: The sequence is R → B → D → C → A → S.
Part No. 3: The sequence is R → E → F → B → A → C → D → S.
Part No. 4: The sequence is R → F → A → C → D → S.
Part No. 5: The sequence is R → C → A → D → S.
 String Diagram
• In a string diagram, circles are used to represent different pieces of
equipment or workstations in a facility, while lines between the
circles show the flow of materials or parts moving from one piece of
equipment to another.

o Flow Lines: These lines are drawn from the middle of one circle to the
middle of the next circle to show the path of movement.
o Jumping Departments: If the flow skips a department, the line is
drawn above the circles it jumps over.
o Backtracking: When the flow goes backward (toward a previous
department), it is called backtracking. This is represented by drawing
the line under the circles to show the reverse direction of movement.
 Fig 5-3: The presence of numerous crossing
and overlapping lines suggests significant
backtracking and inefficient flow,
highlighting the need for improvement.

Fig 5-4: In this setup, the flow lines are

more streamlined with fewer jumps and
crossovers, indicating a more efficient
layout.
• Since the longest
routing sequence is 7
steps (for Parts 1 and
3), the 35 steps (7
steps × 5 parts)
represents an ideal
layout where each part
would move exactly as
needed without any
extra steps.
• This number provides
a theoretical minimum
for comparing the
efficiency of different
layout arrangements.
Multicolumn Process Chart
• A Multicolumn Process Chart is a
visual tool used to map the flow of
multiple parts through various
operations in a facility.

• It shows each part's path side by side,

with operations listed vertically on the
left and columns representing each
part. Circles mark where each part
goes, connecting them to show the
flow.
Multicolumn Process Chart
Purpose:

• Visualize and compare parts' movements.

• Identify inefficiencies like long travel distances or backtracking.

• Help optimize the layout to reduce steps and improve efficiency.

• It is useful for quickly spotting and fixing issues in a production

process to streamline operations and increase productivity.
 Hints
1. Analyze the Routing Requirements: Begin by looking at the routing table and
determining the sequence of operations for each part. Identify which operations
are used most frequently across all parts and note any common sequences.

2. Prioritize Commonly Used Operations: Operations that appear frequently in the

routing of multiple parts are placed closer together. This helps reduce the travel
distance for parts that require those operations.

3. Group Sequential Operations Together: Where possible, arrange operations

that often follow each other (e.g., B and D or A and F) close together. This
minimizes the steps needed between consecutive operations, allowing parts to
follow a more streamlined route.
 Some Hints
4. Minimize Steps for Each Part: The goal is to set up the operations so that
each part follows the shortest possible route through its required sequence.
By rearranging the operations, you can potentially reduce the total number of
steps each part needs to complete its routing, improving overall efficiency.

5. Iterate for Improvement: This process often requires multiple iterations,

adjusting the positions of operations and re-evaluating the total steps needed
by each part until an optimized layout is found.
From-To Chart
• A From-To Chart is a detailed matrix used in manufacturing to optimize layout efficiency
by considering the importance of each part and its movement through operations.
• It tracks where each part moves from and to in the sequence of operations.

• Assigning Penalty Points:

o Close Moves: For moves between nearby machines (e.g., R to A), the weight is
multiplied by 1.
o Farther Moves: For moves farther away (e.g., R to B, which is two blocks away), the
weight is multiplied by 2. This increase continues as the distance grows.
o Backtracking Penalties: Moves below and to the left of the diagonal in the chart
represent backtracking (moving backward). These moves have doubled penalty
points because backtracking is inefficient and costly.
Process Chart
• The Process Chart is a tool used to document every step that a
specific part undergoes from the moment it arrives at the plant
until it is integrated with other parts in production.

• This chart focuses on only one part and provides a detailed

record of each operation, transport, inspection, storage, and
delay it encounters.
Process Chart
Improving Efficiency with the Process Chart
1. Can I eliminate this step? Removing unnecessary steps can save time and cost.
2. Can I automate this step? Automation can improve consistency and efficiency.
3. Can I combine this step with another? Consolidating steps can reduce the time and
effort needed.
4. Can I change the routing to reduce distances traveled? Optimizing the flow reduces
travel time and cost.
5. Can I move workstations closer together? Shorter distances between stations
improve flow.
6. Can I justify production aids to increase effectiveness? Using tools or aids may
enhance efficiency.
7. How much does this part cost to produce? Understanding the cost at each step helps
in making cost-effective decisions.
1.Present Method or Proposed Method:
You choose if you're documenting the current way
(present method) or a new way (proposed method) of
doing things.
2.Date and Page Number:
This is important because, over time, you might need to
know when you recorded this information.
3.Part Description:
It includes its name, specifications, and part number.
Adding a blueprint or drawing helps visualize what the
part looks like.
4.Operation Description:
This tells you which part of the process you're studying,
like from the receiving area to the assembly area.
5.Summary:
This section shows the number of steps (like operations,
transportation, inspection, delays, and storage) for both
the current and proposed methods. It also calculates
the distance traveled and time taken for both methods.
This helps compare the effectiveness of the two
methods.

6.Analysis:

• Why is this step needed?

• What is being done?
• Where and when does it happen?
• How and who is involved?
7.Flow Diagram Attached:
This indicates if a visual flow diagram is attached.
The diagram shows the same process in a picture
form, making it easier to understand and compare
with the written chart.

8.Details of Process:
Each row represents a step in the process,
numbered and described in simple terms. This is
where you write what happens in each step, like
"move part to assembly" or "inspect part.“

9.Method:
This describes how the step is carried out, like
whether a fork truck, hand cart, or conveyor is
used for transportation.
10.Symbols:
The chart uses symbols to show different types of
activities (like operations, transportation, inspection).
This makes it easy to see what kind of activity is
happening at each step.

11.Distance in Feet:
This shows how far the part is moved in each step. It is
important for understanding how much travel is
involved in the process.

12.Quantity:
This column shows how many parts are involved at each
step, such as how many parts are inspected at once or
how many are moved in a batch.
13.Time in Hours per Unit:
This indicates how much time each step takes per unit. It is used to calculate labor costs
and helps identify where time is being used efficiently or wasted.
13.Time in Hours per Unit:
This indicates how much time each step takes per unit. It is used to calculate labor costs
and helps identify where time is being used efficiently or wasted.
14.Cost per Unit:
This is the cost of each step based on the time it takes and the labor rate (e.g., $15 per hour). It
shows how much each part of the process costs.
15.Time/Cost Calculations:
This space is for recording the formulas used to
calculate time and cost, so you can refer back to them
later if needed. It ensures consistency in how costs are
calculated.
Total Plant Flow
• Flow Diagram: Visual representation showing the physical layout of a
plant and the movement of materials or products through it.

• Operations Chart: Focuses on the sequence of operations, showing

what happens at each step in the process, typically with specific
symbols for different types of actions (like operations or inspections).

• Flow Process Chart: A detailed chart that tracks the flow of materials or
work through each step, including transportation, operations, delays,
storage, and inspections.
Flow Diagrams
• Flow diagrams show the paths each part takes as it moves through the
plant, from receiving materials to shipping the final product. This includes
every stage, such as fabrication, subassembly, and packaging.
• The paths are drawn on a layout of the plant to visualize how parts move.
This helps identify issues like:
o Cross Traffic: Where parts move in opposite directions, potentially
causing congestion.
o Backtracking: Where parts have to return to a previous area,
increasing travel distance.
o Distance Traveled: The total length parts move within the plant.
1. Figure 5-3:
• This diagram shows a detailed flow of materials within a facility, including
specific machines, stations, and departments.
• Each process or machine is labeled and includes directional arrows to
indicate the flow of parts through various operations.
• It is more detailed, displaying individual equipment and paths in a factory
setting.

2. Figure 5-4:
• This is a more simplified and high-level layout of a toolbox plant, showing
general areas (e.g., Assembly, Warehouse, Maintenance) rather than
individual machines.
• It focuses on the overall flow between sections rather than specific
machine details, giving a broader overview of the plant layout.
Cross Traffic
• Cross traffic happens when the paths of materials or products cross
each other.
• This is bad because it causes congestion (traffic jams) and can be
unsafe.
• To reduce cross traffic, machines, equipment, and departments
should be arranged better to avoid intersecting paths.
Backtracking
• Backtracking is when materials move backward instead of forward
toward shipping.
• This wastes time and costs more—about three times as much as
moving forward correctly.
• Rearranging departments to avoid backtracking saves time and
distance. Less travel means more productivity.
Distance Traveled
• The farther materials travel, the more it costs.
• A good layout reduces the distance materials need to travel.
• Flow diagrams show how materials move and help identify ways to
shorten travel distances.
• These diagrams are based on production steps (route sheets) and
layouts, and they guide changes to make the process more efficient.
• Always aim to make quality parts in the cheapest, most efficient way
by reducing cross traffic, backtracking, and unnecessary travel
distances
Procedure for Developing a Flow Diagram
Step 1: Start with a Layout
Use an existing or a proposed plant layout that is
drawn to scale.
Step 2: Plot Each Step
Take the route sheet (which shows each step of
making a part) and plot each step on the layout.
Connect the steps with lines to show the flow.
Use colors or other markings to differentiate between
different parts or processes.
Step 3: Assembly Line Flow
After all parts are made, they come together at the
assembly line in a specific order.
The assembly line position is based on where the
parts come from.
From the assembly line, all parts move together to
packaging, warehousing, and shipping.
The Operations Chart Explained

• An Operations Chart is a visual tool that shows all the steps

needed to produce a part or assemble a product from start to
finish.

• It uses circles to represent each operation and organizes them in

a sequence from raw material introduction to the final assembly
and packaging.
 Raw Material Introduction: The chart starts with raw
materials at the top, arranged horizontally.
 Operations and Fabrication Steps: Below the raw
materials, vertical lines connect circles, each
representing an operation required to transform the
material into a finished part.
 Assembly: As the parts are completed, they come
together in the assembly area, flowing from right to left.
The first part starts on the right, and additional parts are
added to the left in the order they are needed.
 Buyout Parts: Some parts are purchased (buyouts) and
don’t need fabrication. These are shown on horizontal
lines above where they are introduced in the assembly
process.
 Packout: The final step involves packaging the completed
product.
Step-by-Step Procedure for Preparing an Operations Chart
Step 1: Identify Parts
• Determine which parts will be made and which will be bought ready-
made.
Step 2: Define Operations
• List all operations needed to make each part and the order they happen
in.
Step 3: Sequence of Assembly
• Decide the order in which purchased and manufactured parts are
assembled.
Step-by-Step Procedure for Preparing an Operations Chart
Step 4: Find the Base Part
Identify the first part to start assembly.

 Draw its name on a horizontal line

at the top right of the chart.
 Draw a vertical line down and place
circles for each operation in the
order they happen.
Step-by-Step Procedure for Preparing an Operations Chart
Step 5: List Other Parts
For each additional part:

 Place its name to the left of the

previously listed part.
 Below each part, list all its fabrication
operations in order, represented by
circles along a vertical line.
 Continue until all parts are listed in
reverse order of assembly (i.e., the last
part added is placed first on the chart).
Step-by-Step Procedure for Preparing an Operations Chart
Step 6: Connect Parts to the
Base Part
Once a part is completed, draw a horizontal
line from the last operation of that part to the
point where it joins the base part.
 Ensure the line connects just above the
first assembly operation of the base
part.
 For multiple parts, connect each to the
base part’s vertical line at the correct
assembly point, ensuring the flow is
logical and clear.
Step-by-Step Procedure for Preparing an Operations Chart
Step 7: Introduce Purchased
Parts
Purchased parts enter the assembly
process at specific points.

 Represent these parts with horizontal

lines that lead to the correct
assembly operation circle where they
are added to the assembly.
Step-by-Step Procedure for Preparing an Operations Chart
Step 8: Add Detailed
Information
Beside each operation circle:

 Write the time standard (how long

each operation takes).
 Include the operation number (to
reference it easily).
 Provide a brief description of the
operation.
Step-by-Step Procedure for Preparing an Operations Chart
Step 9: Total Time
Once all operations are charted, add up
the time required for each operation to
calculate the total time per unit.

 Write the total hours per unit at the

bottom right of the chart under the
last assembly or packing operation.
This gives you a clear view of how long
it takes to produce one complete unit.
Flow Process Chart
• A Flow Process Chart is a detailed and comprehensive tool used to
analyze the production process of a product or part, combining
elements of both operations charts and process charts.

• It includes all steps and types of movements in a manufacturing

process and provides a holistic view of the entire workflow.

• It uses multiple symbols to depict various activities, unlike the simpler

operations chart that uses only one symbol.
Symbols in Flow Process Chart
Symbols in Flow Process Chart
Symbols in Flow Process Chart
• The flow process chart combines elements of the operations chart and the process
chart. This means it tracks not only operations but also other key activities like
transportation, storage, inspection, and delays.

• Operations Chart uses only one symbol, the operation symbol (○). However, Flow
Process Chart uses all five symbols. This makes the flow process chart more detailed
and comprehensive.

• In the flow process chart, buyout parts (purchased parts) are treated the same way
as manufactured parts, meaning they are fully integrated into the process chart like
any other component.

• There is no standard form for flow process charting. This gives designers flexibility to
modify the chart based on the specific needs of the process being analyzed.
Step-by-Step Procedure for Preparing a Flow Process Chart
Step 1: Start with an Operations Chart
 Begin with an existing operations chart that outlines the primary operations and
sequence for each part.
 This serves as the foundation, providing a basic view of the production flow.
Step 2: Complete a Process Chart for Each Part
 Develop a process chart for each individual part, documenting every step from fabrication
to final assembly.
 Include all activities using the five symbols: operations, transportation, storage,
inspection, and delay.
 Ensure the chart captures every movement, inspection, and storage point, as well as any
delays or temporary holds.
Step-by-Step Procedure for Preparing a Flow Process Chart

Step 3: Combine the Operations and Process Charts

 Merge the individual process charts for each part with the overall operations
chart.
 Integrate buyout parts (parts that are purchased complete) into the chart at the
points where they are introduced into the assembly or production process.
 Make sure to connect all parts and steps logically, showing how they move
through the plant, where they are stored, and where inspections take place.
Computer-Aided Flow Design and Analysis

• Using computers and specialized software can greatly

improve how material flows in a manufacturing
facility.
• Instead of physically moving equipment around to
test different layouts, designers can use programs to
see which layout would work best before making any
actual changes.
Computer-Aided Flow Design and Analysis

What the Software Does:

• FactoryFLOW: This is a software tool that helps design and analyze facility
layouts. It combines facility drawings with material flow paths and
production data. It shows how materials move between different stations
(activity centers) in the facility.

• FactoryCAD: This companion software is used to create detailed layouts

of the facility, showing where machines and stations are currently or
could be located.
Computer-Aided Flow Design and Analysis
How It Helps:

• The software allows designers to add a lot of information, like production

volumes, routes that each part takes, and material handling costs.

• Flow diagrams are created, where the thickness of flow lines shows how
often materials are moved between stations. Thicker lines mean more
movement, which usually costs more.

• It can show critical paths (the main routes materials take), bottlenecks
(where movement slows down), and overall flow efficiency, all visually
and through reports.
Computer-Aided Flow Design and Analysis
Benefits:

• Easy Experimentation: Designers can quickly test different layouts by

adjusting the virtual layout, part routes, and production amounts.
Changes can be seen instantly, making it easier to decide which
setup works best.
• Reduce Unnecessary Handling: The software helps identify and
eliminate extra handling steps that don’t add value, saving time and
money.
• Optimized Layout: By comparing different options, the software
helps find the best spots for docks, storage, and equipment to make
the workflow smoother and more efficient.
Computer-Aided Flow Design and Analysis

Visual and Data Output:

• The software shows path diagrams with lines that indicate

movement frequency and costs.

• It also provides reports with detailed information on the cost

and efficiency of different layout and handling options.
Thank you!
Do you have any questions?
[email protected]