Layout Strategy, Material & Inventory Management Flashcards
_____ focuses on designing the physical arrangement of facilities, equipment, and workstations to maximize efficiency, minimize waste, and ensure smooth workflow.
layout strategy
5 types of layouts
- process layout
- product layout
- fixed-position layout
- hybrid layout
- cellular layout
____ Arranging equipment in sequence in sequence for mass production (e.g., assembly lines).
product layout
____ Grouping similar processes together (e.g., hospitals, job shops).
process layout
____ Keeping the product stationary while resources move to it (e.g., ship building).
fixed-position layout
____ Combination of multiple layout for flexibility.
hybrid layout
____ Organizing workstations based on product families to improve efficiency.
cellular layout
4 layout strategy in construction
- process layout
- product layout
- fixed-position layout
- hybrid layout
_____ Site is divided into zones (e.g., materials storage, worker break areas, machinery stations).
process layout
___ For prefabricated construction, materials are placed in sequence (e.g., beams, panels, and finishing materials).
product layout
____ In skyscraper construction, the building remains in place while equipment and workers move around it.
fixed-position layout
____ A mix of prefabrication (off-site) and on-site assembly for modular buildings.
hybrid layout
4 factors affecting layout design
- space utilization
- workflow optimization
- material handling
- safety and ergonomics
4 objective of an effective layout
- improve production efficiency
- reduce material handling and transportation costs
- optimize resource utilization
- enhance worker productivity and comfort
_____ Maximizing available space while maintaining efficiency.
space utilization
____ Reducing unnecessary movements and bottlenecks.
workflow optimization
____ Ensuring a safe work environment to reduce injuries.
safety and ergonomics
____ Minimizing transportation costs and improving accessibility.
material handling
What are the 2 technology integration in layout design?
- automation
- simulation
___ in layout design (AI-driven layouts, robotic workstations).
automation
____ tools to optimize facility design before implementation.
simulation
2 impact on cost and productivity
- reduces waste, labor costs, and material handling expenses
- leads to faster production cycles and increased output
____ refers to the development of computer systems capable of performing tasks that typically require human intelligence, such as learning, problem-solving, and decision-making.
artificial intelligence (AI)
____ ensures the right materials are available at the right time, place, and cost to support production needs.
material management
What are the 3 objectives of material management?
- minimize waste and storage costs
- improve supply chain efficiency
- ensure uninterrupted production
_____ Reduces inventory holding costs by ordering materials only when needed.
just-in-time (JIT)
What are the 3 procurement strategies?
- just-in-time (JIT)
- vendor-managed inventory (VMI)
- bulk purchasing
____ Supplier manage stock levels for manufacturers.
vendor-managed inventory (VMI)
____ Reduces costs but requires proper storage management.
bulk purchasing
What are 3 storage & handling?
- FIFO (first-in-first-out) & LIFO (last-in-first-out)
- warehouse management systems (WMS)
- automated retrieval systems
Storage & handling for material rotations when needed.
FIFO and LIFO
Storage & handling for optimized storage.
warehouse management systems (WMS)
2 steps in supplier management
- evaluating supplier performance based on cost, quality, and reliability
- building strong supplier relationships for better pricing and priority service.
2 technology in material management
- RFID and barcode systems for real-time inventory tracking
- AI-driven demand forecasting to prevent stockouts
Storage & handling to improve efficiency
automated retrieval systems
2 cost control & waste reduction
- implementing lean manufacturing principles
- sustainable sourcing to reduce environmental impact
5 material management in construction
- just-in-time (JIT)
- vendor-managed inventory (VMI)
- bulk purchasing
- materials handling
- RFID tracking
_____ Concrete is delivered in small, scheduled batches to prevent hardening before use.
just-in-time (JIT)
____ The supplier monitors stock levels of cement and aggregates, replenishing them automatically.
vendor-managed inventory (VMI)
___ Large orders of steel bars and cement to get discounts, but requiring careful storage.
bulk purchasing
____Using cranes and conveyor belts to transport heavy materials efficiently.
material handling
____ Each batch of concrete is tagged for quality control and traceability.
RFID tracking
____ involves tracking, controlling, and optimizing, stock levels to meet demand without excess waste.
inventory management
5 types of inventory
- raw materials
- work-in-progress (WIP)
- finished goods
- MRO (maintenance, repair, and operations)
- safety stock (buffer inventory)
____ Basic materials used in construction. example: cement, steel bars, sand, gravel, bricks
raw materials
_____ These materials are procured in bulk and stored until needed for site work.
raw materials
____ Partially completed components. example: pre-cast concrete slabs, fabricated steel beams, ductwork, wooden panels.
work-in-progress (WIP)
____ are semi-finished products that are not yet part of the final structure
work-in-progress (WIP)
_____ Completed items ready for installation. example: Pre-assembled doors, windows, prefabricated wall panels, HVAC units
finished goods
_____ components are fully completed and stored until installation
finished goods
___ Supporting supplies. example: Safety gear, tools, lubricants, spare parts, welding rods
MRO (maintenance, repair, and operations)
_____ items don’t go directly into the building, but are essential for construction activities.
MRO (maintenance, repair, and operations)
_____ Buffer inventory. Extra stock kept for emergencies. example: Extra steel bars, backup cement bags, additional tiles for replacement
safety stock
_____ Stored as a precaution in case of unexpected demand or delivery delays
safety stock
3 inventory control techniques
- economic order quantity (EOQ)
- ABC analysis
- just-in-time (JIT)
____ Determines the optimal order quantity to minimize total costs.
economic order quantity (EOQ)
_____ Categorizes inventory based on importance (A = high-value, B = medium, C = low-value).
ABC analysis
_____ Reduces storage costs by keeping minimal stock.
just-in-time (JIT)
____ Using AI and big data analytics to predict demand fluctuations. Seasonal and trend-based forecasting to manage inventory levels.
demand forecasting
_____ Measures how efficiently inventory is used by calculating sales vs. stock levels.
inventory turnover ratio
____ Integrates inventory with other business processes.
enterprise resource planning (ERP) systems
3 software & automation in inventory management
- enterprise resource planning (ERP) systems
- cloud-based inventory system
- IoT (internet of things)
____ Real-time stock visibility across multiple locations.
cloud-based inventory systems
_____ Smart sensors for real-time inventory tracking.
IoT (internet of things)
6 inventory management in construction
- raw materials
- work-in-progress (WIP)
- finished goods
- safety stock
- inventory turnover ratio
- software integration
_____ Steel beams, cement, bricks, and sand are ordered based on demand forecasts
raw materials
____ Pre-cut steel beams stored near the assembly area for quick access.
work-in-progress (WIP)
____ Prefabricated sections ready for final installation.
finished goods
_____ ensure consistency and efficiency in job performance, while manpower planning focuses on forecasting workforce needs to optimize productivity.
work standards
____ Tracking how quickly materials are used to prevent excess stock or shortages.
inventory turnover ratio
_____ Cloud-based inventory systems help managers track stock levels across multiple project sites.
software integration
_____ Extra steel beams kept on-site to prevent delays due to unexpected demand.
safety stock
3 work standardization
- establishing Standard Operating Procedures (SOPs)
- defining best practices for quality and efficiency
- reducing variablity in performance
A ____ isa detailed, written set of instructions that outlines how to perform a specific task or process consistently and effectively, ensuring uniformity and quality.
standard operating procedure (SOP)
2 time & motion study
- observing tasks to identify inefficiencies
- improving workflows by eliminating redundant steps
2 manpower planning
- workforce forecasting
- skill gap analysis
____ Estimating future labor needs based on production goals.
workforce forecasting
____ Identifying training needs for workforce development.
skill gap analysis
2 automation & workforce balance
- identifying roles suitable for automation
- retraining workers for higher-value tasks instead of repetitive manual labor
2 ergonomics & job satisfaction
- designing jobs to reduce physical strain and improve comfort
- ensuring a balanced workload to prevent burnout
2 performance metrics & monitoring
- key performance indicators (KPIs)
- continuous improvement programs
____ for productivity, efficiency, and quality control.
key performance indicators (KPIs)
_____ Lean Six Sigma for performance optimization.
continuous improvement programs
____ Focuses on efficiency through the minimization of waste errors and delays.
lean
____ Focuses on quality and consistency, through process improvement and variation reduction.
six sigma
____ Delivers Customer Value through efficient operations and quality standards.
lean six sigma
2 designing work standards & manpower planning in construction
- work standardization
- time & motion study
_____ Using standard operating procedures (SOPs) for excavation, framing, and electrical work to ensure consistent quality.
work standardization
_____ Analyzing how long it takes workers to lay bricks per square meter and optimizing workflow.
time & motion study
4 manpower planning
- forecasting the number of workers needed for each phase (foundation, structural work, finishing)
- ensuring a balance between skill labor (electricians, plumbers) and general laborers
- tracking productivity through daily logs
- using key performance indicators (KPIs) like completed square footage per day
Using automatic brick-laying machines to speed up work while retaining manual workers for finishing tasks
automation vs. workforce
2 performance monitoring
- tracking productivity through daily logs
- using key performance indicators (KPIs) like completed square footage per day
Providing proper lifting equipment and safety gear to reduce injuries.
ergonomics & safety
