What are some shortcomings of the traditional approach to designing factories in which we start with the size and shape of the plant, decide where the support facilities go, and then decide where to place the tools? What are some shortcomings ofthe factory physics approach?

The traditional approach to designing factories generally starts with determining the size and shape of the plant. After that, the positions of support facilities, such as offices and restrooms, are established. Finally, the tools and machinery are placed within the factory.

1. Lack of Flexibility: The traditional approach does not easily accommodate changes in production processes or the introduction of new products. This can lead to costly reorganizations of the factory layout. 2. Inefficient Space Utilization: By first focusing on the size and shape of the factory, rather than the placement of production equipment, the traditional approach can lead to inefficient use of space, which can decrease productivity. 3. Limited Focus on Throughput: There is often a lack of focus on maximizing the flow of materials through the manufacturing process in the traditional approach, which can lead to bottlenecks and reduced productivity.

The factory physics approach focuses on the underlying principles of production and uses mathematical models to determine the optimal factory layout. This approach often considers factors such as balancing workloads, minimizing work-in-process inventory, and maximizing throughput.

1. Complexity: The factory physics approach relies on sophisticated mathematical models, which can be complex and difficult to understand for everyone involved in the factory design process. 2. Limited Real-world Applicability: The mathematical models used in the factory physics approach might not always accurately represent the real-world complexities of a factory environment, which could lead to problems when implementing the designed layout. 3. Dependence on Accurate Data: This approach heavily relies on accurate data input, such as production rates and process times. Any errors in these data can significantly affect the layout's effectiveness. In summary, both the traditional and factory physics approaches have their shortcomings. While the traditional approach can be inflexible and lead to inefficiencies, the factory physics approach can struggle with real-world complexities and require significant expertise.