layout. A secondary operation is one that is necessary for the completion of production, but may
interrupt the smooth flow. A secondary operation may be routed from the main lines into branch
lines, to be returned at a point further along the main line. The most common reasons for these
detours are because of facility limitations, safety reasons, complicated or bulky operations, or
operation exceptions that may result in delays (for example, it is discovered on the receiving
dock that only one package out of 50 needs refurbishment).
(5) Included in the flow sheet is a table listing the number of each operation, the personnel required,
the tools to be used, and the materials needed.
(a) Personnel. The number of workers assigned to each operation will be kept at an efficient
Figure 5. Process flow sheet