Material Flow Process Chart, Man Flow Process Chart

Material Flow Process Chart is a tool used in industrial engineering and operations management to visually represent the movement and handling of materials throughout the production process. It provides a clear and systematic depiction of how raw materials are transformed into finished products by tracking their movement, handling, storage, and processing stages. The material flow process chart helps identify inefficiencies, bottlenecks, and areas for improvement in the overall workflow of materials within an organization.

Purpose of Material Flow Process Chart:

• Optimization of Material Movement:

The primary goal of the material flow process chart is to minimize unnecessary material movement, which directly reduces cost, time, and potential damages to the materials. It ensures that materials are only handled when and where they are needed.

• Identification of Bottlenecks:

It helps identify bottlenecks or stages in the material handling process where delays or inefficiencies occur. This allows for strategic decision-making to improve the overall flow.

• Cost Reduction:

By streamlining material handling processes and reducing unnecessary storage, businesses can lower inventory holding costs and waste, contributing to overall cost savings.

• Improved Workflow:

The material flow process chart simplifies the analysis of material movement, offering a clearer understanding of workflows, which is essential for improving layout, reducing transportation costs, and speeding up production.

Components of Material Flow Process Chart:

• Inputs and Outputs:

The chart begins with the raw materials or components that are input into the system. It outlines where these materials are sourced and where they are headed within the production process. The output is the final product or goods ready for distribution.

• Operations:

This part of the chart represents the various operations or activities that the materials undergo during the production process, including processing, assembly, testing, etc.

• Storage:

Locations where materials are stored during production are indicated on the chart. This includes warehouses, stockrooms, and work-in-progress storage. It helps optimize the layout by ensuring that materials are stored close to the point of use.

• Transport:

The chart tracks how materials are transported from one stage of production to another, including forklifts, conveyors, and manual handling.

• Time and Sequence:

The flow chart includes time indicators to show how long materials stay at each point in the process and the sequence in which materials move through the system.

Types of Symbols Used in Material Flow Process Charts:

• Circles: Represent a storage or waiting point.
• Rectangles: Represent a process or operation that materials go through.
• Arrows: Show the direction of material movement.
• Dotted Lines: Indicate inspection or testing steps.

These symbols provide a standardized method for illustrating the material flow process.

Applications of Material Flow Process Chart

• Manufacturing: In industries like automotive or electronics manufacturing, material flow process charts help visualize how raw materials move through different stages of production.
• Logistics and Warehousing: In warehouses, these charts can track the movement of goods and inventory to ensure that the process is streamlined and efficient.
• Retail: Material flow charts can also help in retail operations by tracking the movement of inventory through different stages of the supply chain.

Man Flow Process Chart

Man Flow Process Chart is a similar tool used to analyze and improve human work methods within an organization. It focuses on how workers perform tasks within a process, capturing the sequence and movement of the human resources involved. This chart is primarily used to evaluate labor efficiency and identify areas where the work methods, worker movements, or task sequence can be optimized to improve productivity and reduce unnecessary fatigue or time loss.

Purpose of Man Flow Process Chart:

• Improving Work Methods:

The primary objective of the man flow process chart is to ensure that workers perform their tasks using the most efficient methods, minimizing unnecessary movements and reducing fatigue.

• Eliminating Wastes:

Much like material flow charts, man flow process charts help in identifying wastes related to human work, such as excessive walking, waiting, or unclear task sequencing.

• Labor Efficiency:

By simplifying the work process, improving task design, and identifying repetitive or unnecessary movements, the chart helps in increasing worker productivity and reducing idle time.

• Optimal Utilization of Manpower:

It helps ensure that workers are not under-utilized or overburdened. It enables managers to allocate resources effectively and ensure that each worker’s skills are used optimally.

Components of Man Flow Process Chart:

• Work Activities: The chart shows each step of the work process that an individual performs, starting from receiving the task to completing it. It includes the actions performed and their sequence.
• Worker Movements: This includes all the movements made by the worker, such as walking, reaching, or handling materials. The chart outlines these movements and evaluates whether they can be minimized or eliminated.
• Time Taken: Time spent on each task or movement is recorded to identify areas that can be reduced or optimized. The timing helps in determining whether a task is unnecessarily time-consuming.
• Interactions: The chart also includes interactions with other workers, machines, or equipment. It identifies potential issues related to coordination, waiting times, or communication gaps between workers.

Types of Symbols in Man Flow Process Chart

• Ovals: Represent the start and end points of a task or operation.
• Rectangles: Represent actions or operations that the worker performs.
• Arrows: Indicate the flow of activities or movement of workers between tasks.
• Dotted Lines: Represent waiting times or periods of inactivity.

Applications of Man Flow Process Chart:

1. Manufacturing: In manufacturing settings, it helps optimize worker tasks to ensure that the labor force is used efficiently and that operations are streamlined.
2. Service Industry: In service environments, such as hospitals or restaurants, this chart helps analyze worker interactions with customers and other staff, identifying areas where process improvements can lead to faster service delivery and enhanced customer satisfaction.
3. Warehousing: In warehouses, it can help identify unnecessary movements or poorly designed workflows that lead to inefficiencies and delays in fulfilling orders.
4. Administrative Work: Man flow charts can also be used in offices or administrative work to evaluate office tasks, scheduling, and coordination among workers.

Key differences Between Material Flow Process Chart and Man Flow Process Chart