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Chapter 06 - Process Selection and Facility Layout
6-1
CHAPTER 06
PROCESS SELECTION AND FACILITY LAYOUT
Teaching Notes
Facility Layout involves physical placement of departments and/or arrangement of equipment within a
plant or a service facility. A good layout will possibly lead to smooth flow of material, reduction of
inventories, and effective utilization of space.
The material in this chapter can be divided into four areas:
1. Process types, process selection and automation.
2. Classification of production systems and (corresponding) types of layouts.
3. Line balancing.
4. Designing process layouts.
This chapter provides a good lead-in for the following chapter on design of work systems because it
introduces some of the problems that can be associated with work systems. It also describes group
technology, cellular manufacturing, and flexible manufacturing systems.
Operations Tour: Morton Salt
1. Steps in salt production for Morton are:
a. Inject water into salt caverns below the surface and let the salt deposits dissolve in the
water.
b. Pump the resulting brine to the surface.
c. Boil the brine, let the liquid evaporate leaving salt crystals and residual moisture.
d. Dry the salt to remove the residual moisture.
e. Store the salt in silos.
f. Move the salt to dedicated production areas.
g. Produce the cans by forming a cylinder (two sheets of chip board are glued together) .
h. Roll the cylinder into a continuous tube.
i. Cut the tubes into can-size pieces.
j. Assemble and glue the separate pieces constituting the can.
k. Fill the cans with salt.
l. Load the filled cans onto pallets and store them in inventory.

6-2
2. Quality is checked during different stages of the production process.
a. Check salt for purity using chemical analysis.
b. Assure appropriate crystal size by forcing the salt through a scraping screen.
c. Remove the small pieces of metal by magnets at different stages of the process.
d. Check the weight of the filled cans, attach the label sticker.
e. Check to make sure that metal pour spouts are correctly attached.
3. The company may not have updated its equipment because of the high cost of investment in
new machinery.
4. Salt production would be a low variety, high volume operation which would place it as a
repetitive production or continuous flow in the product-process matrix.
5. (3,800,000 cans per year) x (26 ounces of salt per can) = 98,800,000 ounces per year.
(98,800,000 ounces per year) / (16 ounces per pound) = 6,175,000 pounds per year.
(6,175,000 pounds per year) / (2000 pounds per ton) = 3,087.5 tons of salt per year.
6. Suggested improvements include the following:
a. Application of Statistical Process Control (SPC) to reduce the cost of quality.
b. Develop a plan to overhaul the existing equipment and to purchase new equipment as a
joint effort among finance, purchasing and manufacturing areas.
c. Synchronize production, distribution and capacity planning to make sure that there is
sufficient capacity in the silos to handle the incoming salt from brine production.
Reading: Tour De Force
1. The Viper/Prowler assembly plant is much smaller than typical automobile assembly plants.
The plant covers 392,000 square feet of space as opposed to other typical auto assembly plants
that cover from 2 million square feet to 5 million square feet of space.
The production capacity of the Viper plant is much less than a typical automobile assembly
line. The Viper plant’s daily production capacity is 13 Vipers and 20 Prowlers compared to
large automobile assembly plants that can manufacture 1000 vehicles per day.
While most large automobile plants require 2000 or more workers, the Viper plant employs
only 260 employees.
The Viper plant employs skilled “craftsman” workers. Typical auto assembly plants use
workers to do repetitive work with little skill required.
There are no robots or automation in the Viper plant while most auto assembly plants have
high levels of automation.
The Viper plant uses early 20th
century manual assembly techniques on two manual, parallel,
relatively short (12 work stations and 720 feet long) assembly lines with generous idle time
built in. Typical assembly lines usually involve the use of robots, large number of
workstations and very little idle time.

6-3
2. The reasons for not having robots or other high level automation include the following:
Chrysler Corporation wants to portray a high quality image of two handcrafted automobile
models that is generally more expensive and appealing to high-income individuals. The
personal attention to the customers is part of the marketing package associated with both
products.
The company also wants to draw attention to this facility and the two car models (Viper and
Prowler) manufactured at this facility because it is an unusual and attractive automobile
manufacturing facility. Chrysler Corporation is hoping that not only will it draw attention to
the two hand-crafted automobile models produced within the facility but also possibly
improve the general goodwill associated with the company.
Reading: Designing Supermarkets
This reading provides the student with an example of how a supermarket is laid out and why the
arrangement is done in a particular or specific way. It is a nice change of pace from the typical
manufacturing layout article.
Answers to Discussion and Review Questions
1. Process selection refers to the ways organizations choose to produce or provide their goods
and services. It involves choice of technology, type of processing, and so on. These choices
have important implications for capacity planning, layout of facilities, equipment choices, and
the design of work systems.
2. There are five basic process types:
a. Job-shop: Job-shop is used when a low volume and a large variety of goods or services are
needed. Job-shop involves intermittent processing, high flexibility, skilled workers,
relatively large work-in-process inventories and general-purpose machinery. An example
is a tool and die shop that is able to produce a wide variety of tools.
b. Batch: Batch processing is used when a moderate volume of goods and services is
demanded. It is designed to handle a moderate variety in products. The processing is
intermittent. The flexibility of the process to produce a variety of goods, the skill of the
workers, amount of work-in-process inventories are all less than job shop. A typical
example of batch processing is paint manufacturing.
c. Repetitive: This type of a process involves higher volumes of more standardized goods or
services. The flexibility of the process to produce a variety of goods, the skill of the
workers, amount of work-in-process inventories are all less than batch process. Typical
examples for this type of process include appliances and automobiles.
d. Continuous: This type of a process involves very high volume of highly standardized
goods or services. These systems have no flexibility in output or equipment. Workers are
generally low skilled and there is no work-in-process inventory. The machines are
dedicated to perform specified tasks. Typical examples include petroleum products, steel
and sugar manufacturing.

6-4
e. Project: Projects are designed to be used with non-routine, unusual tasks or activities.
These activities are generally not repeated. Equipment flexibility, level of worker skills
and work-in-process inventory can range from very low to very high. Examples include
construction of a dam or a bridge, conversion of the production system from job-shop to
group technology, installing and implementing a new inventory and bar coding system.
3. Advantages: Highly uniform output, boredom and fatigue are not factors, machines don’t go
out on strike, etc.
4. Numerically controlled (N/C) machines are programmed to follow a set of processing
instructions based on mathematical relationships. Robots have movable arms that enable them
to handle a wide variety of tasks such as welding, assembly, loading and unloading machines,
painting, and testing.
Flexible manufacturing systems (FMS) are groups of machines that have a supervisory
computer, automatic material handling, and automatic processing. Systems usually range from
3 machines to a dozen. They are designed to handle a variety of processing requirements
(similar to intermittent systems) with some of the benefits of automation.
Computer-integrated manufacturing (CIM) is a system for linking manufacturing activities
through an integrated computer. These include engineering design, flexible manufacturing
systems, and production planning and control.
5. (See question #4 above for description.)
6. Process selection decisions often include aspects that require highly technical knowledge.
Many managers do not possess such expertise. However, if those decisions are delegated to
engineers or others who do have the expertise, there is the danger that managerial issues will
suffer. The solution is for managers to increase their knowledge of technological advances. In
the meantime, managers must be prepared to ask questions and impress upon technical experts
their goals and objectives.
7. Managers sometimes view flexible systems as a hedge; hence, they opt for such systems
without having complete understanding of future needs, reasoning that their lack of knowledge
is offset by the flexible nature of the system. However, such systems are more expensive to
install and maintain. Moreover, the flexibility provided by such systems may not be needed, or
it may be of the wrong type. In many cases, a dedicated, or focused system, would be a better
choice.
8. The trade-offs between product layout and process layout include the following:
a. Process layout has more equipment flexibility.
b. Process layout generally has higher skilled workers.
c. Product layout involves higher volume manufacturing.
d. Process layout benefits from high flexibility to be able to produce a variety of products,
while product layout benefits from large volume manufacturing at low cost.
e. The major goal of process layout is to minimize the transportation and material handling
costs while the primary objective of the product layout is to minimize idle time and
maximize efficiency of the process.
f. The utilization of process layout generally results in higher levels of work-in-process
inventory than the product layout.

6-5
g. For a product layout, the flow of work is straight, while for process layout, the flow of
work is mixed depending on the product produced.
h. There is more dependency between workstations for product layout than for a process
layout.
i. The preventive maintenance and machine reliability are more important in a product
layout than process layout because equipment breakdown may involve shutting down a
work station which may in turn result in shutting down downstream work stations.
j. Routing and scheduling is much less complicated for processes with product layout than
processes with process layout.
9. The most common reasons for redesign of layouts include:
a. Inefficient operations.
b. Accidents or safety hazards.
c. Changes in the design of products or services.
d. Introduction of new products or services.
e. Changes in the volume of output or mix of outputs.
f. Changes in methods or equipment.
g. Changes in environmental or other legal requirements.
h. Morale problems
10. Product layouts are generally characterized by specialized labor and equipment designed for
continuous processing. The layout is often arranged on the basis of processing sequence.
Process layouts are more general in nature, in terms of labor, processing equipment and
material handling equipment. Process layouts often feature machine groups or departments.
Items processed in process layouts tend to follow differing paths through the system. Fixed
position layouts are used to facilitate processing of a single (usually large) job, such as
construction of a large building or a hydro-electric power plant. Labor, equipment and
materials are typically brought to the job site (i.e., to the “product”) rather than the other way
around. Fixed position layouts are commonly found in farming, road building, home
remodeling and mining.
11. The main advantages of product layouts include:
a. A potentially high rate of output.
b. Low unit costs.
c. Low training costs and wide span of supervision due to specialization.
d. Low unit cost for material handling.
e. High utilization of labor and equipment.
f. Routing and scheduling are built into the design.
g. Accounting, purchasing and inventory control are fairly routine.
The main disadvantages of product layouts include:

6-6
a. Specialization can mean dull, repetitive jobs with little opportunity for personal
satisfaction or creativity.
b. Workers may have little interest in maintaining equipment or in the quality of output.
c. The system is not particularly adaptable to changes in process design or changes in the
volume of output.
d. The system is highly susceptible to shutdowns caused by equipment failure or excessive
absenteeism.
e. Preventive maintenance costs and the capacity for quick repairs are necessary to ensure
high utilization.
f. Incentive plans tied to individual output are impractical.
12. The main advantages of process layouts are:
a. They can handle a variety of processing requirements.
b. The system is less vulnerable to equipment failures than product layouts.
c. The general purpose equipment used is often less costly than the specialized equipment
used in product layouts. It is also usually easier and less costly to maintain and repair.
d. Individual incentive systems are possible.
The main disadvantages of process layouts are:
a. In-process inventory costs can be high (manufacturing).
b. Routing and scheduling must be done for each new job.
c. Equipment utilization rates are usually low.
d. Material handling is slower, less efficient, and more costly per unit than with a product
layout.
e. There is often a lower span of supervision compared to a product layout.
f. Unit costs tend to be higher than comparable output produced with a product layout.
g. Accounting, inventory control and purchasing are generally more involved than with a
product layout.
13. The main goal of line balancing is to achieve a set of task groupings at work stations in the
line that have equal time requirements in order to get a high utilization of labor and
equipment. Unbalanced lines have bottlenecks at some work stations and idle time at others.
The resulting output is lower than it would be if the line were balanced.
14. Routing and scheduling are continual problems in a process layout because a variety of jobs
pass through the system, and they tend to differ in terms of routing and schedule requirements.
In contrast, product layouts typically handle items with little or no variety—all have the same
or similar routing and scheduling requirements.

6-7
15. With a product layout, equipment breakdown has serious implications because the separate
pieces of equipment are closely tied together. If one piece of equipment fails, the line will
quickly come to a halt. Consequently, preventive maintenance to reduce the failure rate is
advisable. In contrast, a process layout often contains duplicative equipment so that if one
particular piece of equipment fails, the work can usually be shifted to another piece of
equipment. Consequently, there is less need for preventive maintenance, and less need for
repair of equipment when it does break down. Moreover, process layouts utilize more skilled
workers who tend to take better care of the equipment than their lower skilled counterparts in
a product layout system.
16. Job sequence usually determines the arrangement of equipment in a product layout. In a
process layout, job sequences vary, so there is much less influence on equipment arrangement.
Because of differences in job requirements, sequencing is a continual task in a process layout.
17. The subway system is essentially a fixed-path arrangement—a product layout. Its advantages
are often low operating cost, more efficient handling, and low cost per unit moved. On the
other hand, a bus system is more flexible in terms of varying routes. This can be desirable if
there are shifts in which potential riders are coming from and going to. For example, a new
bus route could easily be established to service a new shopping area, a new apartment
complex, or a large industrial facility. Other considerations are initial cost (high for subway
and relatively low for bus), severity of difficulties that would arise from a breakdown (high for
subway, low for bus), the possibility of alternative uses (none for subway, private groups, etc.,
for bus during off times), and possible disruptions caused by weather (higher risk for bus than
subway—e.g., snowstorms stall highway traffic).
18. Fixed-path material handling equipment in supermarkets includes the belts at the checkouts
which move items up to the cashier, the roller conveyors which transport boxes of groceries
outside to pickup areas, conveyors in the meat department to move carcasses from storage to
cutting tables, roller conveyors to off-load goods from trucks and move them to storage.
Variable-path material handling equipment includes grocery carts, “trucks” and “jeeps” used
to transport baked goods from storage to display shelves, and movable racks to transport
baked goods from ovens or from deliveries to the bakery counter.
19. Heuristic approaches are rules designed to guide decision-makers to satisfactory decisions by
reducing the number of alternatives that must be considered. They do not necessarily yield
optimal solutions. They are usually employed when there is a problem involving an
exceedingly large number of potential solutions and an optimizing algorithm is not available.
20. Nonmanufacturing environments do not usually lend themselves to product layouts because
they tend to involve more processing variety than many manufacturing environments.

6-8
21. The original car was probably one of a large number of similar cars produced on an assembly
line, which was set up to speed the flow of work. That is, inventories of parts were on hand,
specialized machinery, workers and material handling equipment were arranged specifically
for the job. As a result of this continuous processing, the unit cost of the car was relatively
low. In contrast, constructing a car from “scratch” is essentially a cross between intermittent
processing and a project, with none of the economies of continuous processing. A list of the
parts must be assembled. Some might be available locally, but others would have to be
shipped individually from suppliers. The parts would have to be held until all were on hand.
Workers would not be highly familiar with this particular car, even though they were
experienced in this sort of work. Consequently, the work would progress at a fairly slow rate,
and probably with a certain amount of back-tracking. Obviously, construction of a
replacement would be considerably more costly than initial, continuous production.
22. Layout can lead to high productivity if it contributes to a smooth flow of work with high
utilization of labor and equipment. This requires careful consideration of future work
requirements to determine what will be needed and a certain amount of effort to obtain an
optimal (or satisfactory) layout. A poor layout will hinder productivity with bottlenecks, lower
utilization of labor and equipment than is necessary, and require more handling or movement
between work stations than is necessary (particularly in process layouts).
23. In cellular manufacturing, machines are grouped into cells. The basis for grouping can be
operations needed to process a group of similar items or part families. Advantages of such
systems include relatively short throughput time, reduced material handling, less work-in-
process inventory, and reduced setup time.
24. Group technology involves items that have similar design or processing requirements and
grouping them into part families for cellular manufacturing. It also includes a coding system
for items.
25. Although we treated the task completion times as fixed in balancing assembly lines, it is more
realistic to assume variable task times whenever humans are involved. The lower the level of
automation, the higher the variability of tasks. If the assembly line consists of tasks with
variable completion times, it will be more difficult to balance the line. In order to deal with
variability of task times, we can require a minimum amount of slack to be available at each
workstation. As the variability of task times increase we can increase the minimum slack
available at each workstation. In addition, workstation slack time can also be used for slower
or less experienced workers who take longer than normal to complete a task.
Taking Stock
1. The three major trade-offs in process selection are:
a. Flexibility vs. efficiency in facilities layout. Product layout is designed to provide efficient
operations, while process layout is designed to provide a variety of products, thus offering
a flexible system.
b. Level of automation (high vs. low) High level of automaton has the potential advantage of
providing faster production or service, the ability to quickly switch from product to
product resulting in higher flexibility. On the other hand, high level of automation
involves higher cost and the potential risk that it may involve costly implementation
problems.

6-9
c. The expected volume of output can either be high or low. If it is high, we can take
advantage of the economies of scale and reduce costs and improve efficiency. However, if
we make a commitment to high volume production and the demand is consistently low,
we may be faced with the potential problem of low efficiency and low utilization of the
machines and idle resources. On the other hand, if the expected volume is low, then we
probably have decided to compete as a job-shop, emphasizing flexibility. If there is a
capacity-demand mismatch, we will either have too few resources allocated for production
or we will have a capacity constraint on resources.
2. If we rebalance the assembly line too frequently, then the cost of making the adjustments
becomes too costly. On the other hand, if we do not rebalance it as frequently as necessary,
then the assembly line will experience too much inefficiency resulting in a less efficient line.
3. In process selection, we must make sure that manufacturing group(s), maintenance,
engineering, technical support, marketing, process design specialists, quality, finance
(especially if we need capital to support the facility layout, new equipment or new machinery)
are involved. Of course we also need to make sure that there is a representative from top
management to ensure that we stay consistent with the overall goals and objectives of the firm.
4. In layout design, we must make sure that manufacturing group(s), maintenance, engineering,
technical support, process design specialists, quality, finance (especially if we need capital to
support the facility layout, new equipment or new machinery) are involved.
5. Technology has tremendous impact on process selection due to changes in computer related
technology. The level of automation continues to change in companies affecting the layout
decisions. For example, the newer machinery are smaller, therefore the size of the machinery
affects the work area size and ultimately the layout of the facility.
Critical Thinking Exercises
1. Student answers will vary.
2. Factories—type of machines, skill level of the employees, level of automation, inventories,
safety.
Supermarkets—maximizing sales potential, minimizing inventory investment, level of
automation, type of automation, number of cashier lines, proximity and location of various
departments within the supermarket.
Department store—maximizing sales potential, minimizing inventory investment, level of
automation, type of automation, proximity—distance and location of various departments
within the department store, capacity and convenience of the parking lot.
3 Factors that must exist in order to make automation feasible are:
a. The level of demand: The demand must be forecasted. Generally, we need high volume of
output to justify the high cost associated with automation.
b. The degree of variability required in the manufacturing or the service system: The higher
the degree of variability required, the less the chance of success for automation.

6-10
Strategic fit with the overall goals and objectives of the company: If the type of automation
does not lend itself to flexible manufacturing, but the objectives and goals of the company
involve low volume large variety of products, we could have significant capacity-demand
mismatch problems due to this misalignment.
For production, the risks relate to the possibility that demand will increase, and it will be
costly to adjust the process to meet that increase, or that it will decrease and leave excess
capacity, and fewer units to absorb costs. In addition, employee morale may suffer if
employees fear losing jobs. For service (e.g., automated call center), customers may prefer
talking to an actual person, or the system may not be able to handle the variety of requests or
demands from customers.
Memo Writing Exercises
1. In most cases it is not feasible to perfectly balance a production line. First, there are
technological constraints dealing with precedence and incompatibility issues. In other words,
certain tasks have to be performed before others (precedence) and two tasks may not be
performed at the same station due to their incompatibility (space and nature of operation
considerations). Secondly, there are output constraints. Since most task times vary, output
constraint determines whether an otherwise eligible task will fit at a workstation because sum
of the task times assigned to a station cannot exceed the cycle time. As a result of both
technological and output constraints, it is extremely difficult to achieve a perfectly balanced
production line. The larger the number of tasks, the more difficult it is to achieve perfect
balance.
2. Producing two products on the same assembly line allows the company to utilize the same
workstations to produce the common parts. This results in synergy on the line. If one of the
products is new, the company can shorten the period of time from design to actual production,
and reduce the cost of manufacturing in the long run.
3. Fixed automation is utilized in a continuous flow/mass production environment. It enables the
firm to manufacture a single or a few products at high volume and low cost. However, it is not
flexible enough to produce a variety of parts and it is very costly to make changes to the
process. Flexible automation is utilized in a job shop (intermittent) environment, where a wide
variety of products can be produced without significant changeover (setup) time/cost. Flexible
machinery is not designed for high volume (mass) production.

6-11
Solutions
1. OT = 450 minutes
a. Minimum cycle time = length of longest task, which is 2.4 minutes.
Maximum cycle time =  task times = 18 minutes.
b. Range of output:
units
25
18
450
:
.
min
18
@
units
5
.
187
4
.
2
450
:
.
min
4
.
2
@
=
=
c. 8
to
rounds
which
,
5
.
7
450
)
18
(
5
.
187
OT
t
Dx
N =
=

=
d. cycle
per
minutes
6
.
3
125
450
CT
CT,
for
Solving
CT
OT
Output =
=
=
e. Potential output:
(1) units
50
9
450
CT
OT
:
.
min
9
CT =
=
=

6-12
(2) units
30
15
450
:
.
min
15
CT =
=
2.
Desired output = 33.33 units per hour
Operating time = 60 minutes per hour
unit
per
minutes
80
.
1
hour
per
units
33
.
33
hour
per
minutes
60
output
Desired
time
Operating
CT =
=
=
a.
Task Number of following tasks Positional Weight
A 7 6
B 6 4.6
C 2 1.6
D 2 2.2
E 2 2.3
F 1 1.0
G 1 1.5
H 0 0.5
0.6
0.7
0.8
0.5
1.0
0.5
0.5
1.4
c
f
h
g
d
e
b
a

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when it was known that this bill had encountered the fate of its
predecessor. Mr. Clay did not scruple to denounce the exercise of the
veto, as he had denounced it in the case of general Jackson, as
unjustifiable, and as involving a manifest encroachment upon the
liberties of the people.
With the solitary exception of Mr. Webster, the cabinet resigned
their seats, and the feeling of indignation, enkindled at Washington,
spread through and lit up the whole country into a glow of wrath, at
the uncalled for and unexpected procedure of Mr. Tyler.
Although baffled, and in a measure defeated, by the despotism
of one man, still Mr. Clay did not slacken his exertions to render
relief to his suffering and distracted country. He was at the head of
two important committees, and performed an amount of labor truly
surprising. He had the gratification of witnessing the repeal of the
abominable sub-treasury scheme, the passage of the bankrupt law,
and his land bill.
An attempt to adjust the tariff was made, which occasioned
another veto from the president. This was directed mainly against
the distribution clause, which was finally surrendered to
accommodate the views of the president. The tariff bill at length
became a law.
On the thirty-first of March, 1842, Mr. Clay executed his long and
fondly cherished design of retiring to the quiet of private life. He
resigned his seat in the senate, and presented to that body the
credentials of Mr. Crittenden, his friend, and successor. The scene
which ensued when he tendered his resignation, was indescribably
thrilling. It was not unlike that, when the father of his country,
surrounded by his companions in arms, pronounced his farewell
address, as they were about to disband and enter upon the
possession and enjoyment of that independence which their
invincible arms had won. Had the guardian genius of congress and
the nation been about to take his departure, and giving his parting

admonitions, deeper feeling could hardly have been manifested,
than when Mr. Clay rose to address, on this occasion, his
congressional compeers. An individual witnessing the breathless
silence that pervaded the densely crowded senate chamber, and the
tears flowing freely and copiously from the eyes of all, would have
said, that wherever else Mr. Clay might have enemies, he had none
in that assembly. In those who were politically opposed, and in those
who were personally hostile to him, the movings of the best
principles of our being were not subjected to the cruel control of
selfishness or envy, but permitted to respond to the voice of nature,
calling them in her most enticing tones to unite with his devoted
friends, in bearing appropriate testimony to his public worth. The
former no less than the latter, manifested the most sincere regret at
the prospect of his departure. All felt that a master spirit was bidding
them adieu—that the pride and ornament of the senate and the
glory of the nation was being removed, and all grieved in view of the
void that would be made. He spoke as it might be expected the
patriot warrior of a thousand victorious battles would speak,
standing on the field where they were fought—the living, burning,
sublime sentiments of patriotism. His feelings often overpowered
him. His voice, naturally musical, seemed the very refinement of
sweetness and pathos, whose honied accents sank into the hearts of
his hearers, like heaven’s benediction. When Mr. Clay closed, the
most intense emotion agitated the senate. Mr. Preston rose, and
remarked, in view of it, that he presumed there would be little
disposition to transact business; that the event that had just
occurred, was an epoch in the legislative history of the nation, and
that therefore he would move that the senate adjourn. The motion
was adopted unanimously.
His resignation as senator did not by any means close his
intercourse with his fellow-countrymen. He still labored for his
country; and by letters from his residence in Kentucky, and by
speeches delivered there and elsewhere, frequently sent forth his
opinions on the various topics of the day. The Whig party had long
regarded him as their most prominent candidate for the chief

magistracy, and he was nominated by acclamation in the convention
of 1844, when ‘Justice to Henry Clay,’ was the watchword of the
contest. He was defeated, however, by the late James K. Polk, who
unexpectedly received the democratic nomination, and remained in
retirement until after the election of General Taylor to the
Presidency. In compliance with the earnest wishes of his political
friends he consented to resume his seat in the senate, and in 1849
was again elected to that honorable position. During the exciting
session of 1849–50, all his energies were devoted to securing the
passage of the series of measures known as the ‘Compromise Acts,’
and there is no doubt that his incessant and intense labors upon the
multifarious schemes which engrossed the attention of congress,
occasioned serious debility and hastened his death. When, in the
winter of 1850–51, it became but too evident that his disease was
gaining the mastery over him, he visited New Orleans and Havana,
in the hope that travel and relaxation, united with the effects of
change of climate, would renovate his physical system. No
permanent advantage, however, resulted from this experiment, and
he was again induced, by a consciousness of his failing health, to
resign his seat in the senate—the resignation to take effect on the
6th of September, 1852. But he was not destined to see that day. He
became gradually weaker and weaker, and was confined to his room
in Washington for several weeks, where he breathed his last on the
morning of the 29th of June, 1852, at seventeen minutes past
eleven o’clock. No one was present at the time, except his son,
Thomas Hart Clay, and governor Jones, of Tennessee. His last
moments were calm and quiet, and he seemed in full possession of
all his faculties, apparently suffering but little. He did not speak for
many hours before his dissolution, but his countenance indicated a
happy resignation and full knowledge of his condition. He had long
previously made every preparation for death, giving his son full
instructions as to the disposition of his body and the settlement of
his worldly affairs.
Perhaps the death of no individual since that of the revered
Washington ever spread such a universal gloom over the country. In

all the principal cities of the Union, funeral honors were paid to his
memory, which were heartfelt and sincere, and evinced a pervading
feeling in the public mind that a great benefactor and friend was no
more. In the Senate and House of Representatives, as will be seen
by the subjoined proceedings, every one seemed anxious to testify
his respect for the memory of the great man who had so long
figured in our national councils. Political differences were forgotten,
and all parties united in rendering homage to his transcendent worth
and in mourning his irreparable loss. A committee was appointed to
attend his remains to Kentucky, where they now repose.
We shall not attempt an analysis of his mind, conscious of our
inability to do it justice. Its powers were so numerous and so great,
as to make the task no light one. Its most prominent attribute was
patriotism. This was the sun of its lofty faculties, which revolved
about it in the order of satellites. Every thing was subordinate to, or
absorbed by it. This was seen in every part of his career, towering
magnificently upwards, like a mighty mountain, to bathe its head in
everlasting sunshine, and formed its loveliest and most attractive
feature. With Mr. Clay, patriotism was no unmeaning word. He made
it the grand test of both principle and measure, and the main-spring
of action. His devotion to it was most remarkable; so exclusive, as to
lead him to sacrifice every other consideration upon its altar. On one
occasion, acting under its influence, he said to Mr. Grundy, ‘Tell
general Jackson, that if he will sign that bill (the land bill), I will
pledge myself to retire from congress, and never enter public life
again;’ of such vital importance did he consider that bill to the
welfare of his beloved country. One cannot avoid breaking out in
exclamations of admiration, and reverence, even, in view of such
self-immolating political purity, as this sincere declaration evinces.
My country, my country, seems to have been the constant apex of
his thoughts and wishes. This attribute gave to his commanding
eloquence its invincible power, and was the rocky pedestal on which
he reared the temple of his immortal fame.

Political consistency was another prominent characteristic of
Mr. Clay. This, like a line of light, is traceable through all his public
life. The soundness of his judgment was worthy of note, by which he
was enabled to predict, with almost prophetic accuracy, the effect of
the adoption of certain measures. As a writer, Mr. Clay’s style was
nervous, perspicuous, and concise, evincing the freshness and
beauty of originality, usually moving on in a deep and quiet current,
but at times rushing like the mountain torrent, overthrowing all
obstacles. He was peculiarly qualified for the regions of argument
and close investigation, yet he could soar into that of imagination,
and whenever he did, it was the flight of the eagle towards heaven.
His power of illustration was felicitous, demonstrating an intimate
acquaintance with the secret springs of the soul, and a sagacious
knowledge of its mysterious movements. His conversational faculties
were striking, and exceedingly versatile, enabling him to
accommodate himself to the capacities of all, to the humblest, as
well as to the loftiest intellect. It was remarked of Mr. Burke, by Dr.
Johnson, that if a tempest, or any other occurrence, should cause
him to take shelter under the roof of a peasant, he would find
sufficient topics to employ his conversational powers, and would so
employ them as to leave indelibly impressed upon the mind of its
lowly occupant, the belief, that he was listening to no ordinary man.
This would be emphatically true of Mr. Clay, who possessed, in an
eminent degree, the faculty attributed to Mr. Burke. It was the
exercise of this, that so endeared him to those who were privileged
to come within the sphere of its influence, which invested his
domestic and social relations with their greatest charms.
In private life, Mr. Clay exhibited the noblest characteristics of
human nature, which may be expressed by one word—
openheartedness. He was kind and liberal to a fault. Says one who
was intimate with him, ‘his door and his purse were alike open to the
friendless stranger and the unfortunate neighbor. Frank, open, and
above the meanness of deception himself, and consequently never
searching for duplicity and treachery in those around him, he more

than once suffered from the vile ingratitude of men who have been
cherished by his bounty and upheld by his influence.
‘The curse of aristocracy never chilled the warm flow of his
natural feelings. His heart continued as warm, his hand as free, and
his smile as familiar as they were when, without friends and without
influence, he first responded to the hearty welcome of the
Kentuckian. His feelings never changed with his fortunes.’
Mr. Clay was admirably qualified for the interchange of social and
friendly feelings, in which he indulged most judiciously. His convivial
interviews were enlivened by enjoyments of a marked intellectual
character. His readiness at repartee, and aptitude for reply, were
conspicuous features in his character. No emergency, however
sudden or unexpected, found him unprepared, or disarmed him. He
perceived the bearing of remarks, with the quickness of intuition,
however vague or ambiguous they might be, and, with the
suddenness of thought, framed and uttered a suitable reply.
Perhaps we cannot better close this imperfect memoir than by
appending the following eloquent tribute from the pen of GEORGE D.
PRENTICE, Esq. It originally appeared in the Southern Ladies’ Book, for
June, 1853, and has been extensively republished in other
periodicals—an evidence of its claim to preservation in a less
perishable form.
HENRY CLAY.

With voice and mien of stern control
He stood among the great and proud,
And words of fire burst from his soul
Like lightnings from the tempest cloud;
His high and deathless themes were crowned
With glory of his genius born,
And gloom and ruin darkly frowned
Where fell his bolts of wrath and scorn.
But he is gone—the free, the bold—
The champion of his country’s right;
His burning eye is dim and cold,
And mute his voice of conscious might.
Oh no, not mute—his stirring call
Can startle tyrants on their thrones,
And on the hearts of nations fall
More awful than his living tones.
The impulse that his spirit gave
To human thought’s wild, stormy sea,
Will heave and thrill through every wave
Of that great deep eternally;
And the all-circling atmosphere,
With which is blent his breath of flame,
Will sound, with cadence deep and clear,

In storm and calm, his voice and name.
His words that like a bugle blast
Erst rang along the Grecian shore,
And o’er the hoary Andes passed,
Will still ring on for evermore.
Great Liberty will catch the sounds,
And start to newer, brighter life,
And summon from Earth’s utmost bounds
Her children to the glorious strife.
Unnumbered pilgrims o’er the wave,
In the far ages yet to be,
Will come to kneel beside his grave,
And hail him prophet of the free.
’Tis holier ground, that lowly bed
In which his mouldering form is laid,
Than fields where Liberty has bled
Beside her broken battle-blade.
Who now, in danger’s fearful hour,
When all around is wild and dark,
Shall guard with voice, and arm of power,
Our freedom’s consecrated ark?
With stricken hearts, Oh God, to Thee,
Beneath whose feet the stars are dust,
We bow, and ask that thou wilt be

Through every ill our stay and trust.

OBITUARY ADDRESSES
ON THE OCCASION OF
THE DEATH OF THE HON. HENRY CLAY;
DELIVERED IN THE
SENATE AND THE HOUSE OF
REPRESENTATIVES,
AND
THE FUNERAL SERMON,
PREACHED IN THE CAPITOL, JULY 1, 1852,
BY THE REV. C. M. BUTLER, CHAPLAIN OF THE SENATE.

SENATE OF THE UNITED STATES, WEDNESDAY,
JUNE 30, 1852.
AFTER the reading of the Journal, Mr. Underwood rose, and
addressed the senate as follows:
MR. PRESIDENT: I rise to announce the death of my colleague,
Mr. Clay. He died at his lodgings, in the National Hotel of this city, at
seventeen minutes past eleven o’clock yesterday morning, in the
seventy-sixth year of his age. He expired with perfect composure,
and without a groan or struggle.
By his death our country has lost one of its most eminent citizens
and statesmen; and, I think, its greatest genius. I shall not detain
the Senate by narrating the transactions of his long and useful life.
His distinguished services as a statesman are inseparably connected
with the history of his country. As Representative and Speaker in the
other House of Congress, as Senator in this body, as Secretary of
State, and as Envoy abroad, he has, in all these positions, exhibited
a wisdom and patriotism which have made a deep and lasting
impression upon the grateful hearts of his countrymen. His thoughts
and his actions have already been published to the world in written
biography; in Congressional debates and reports; in the Journals of
the two Houses; and in the pages of American history. They have
been commemorated by monuments erected on the wayside. They
have been engraven on medals of gold. Their memory will survive
the monuments of marble and the medals of gold; for these are
effaced and decay by the friction of ages. But the thoughts and
actions of my late colleague have become identified with the
immortality of the human mind, and will pass down from generation
to generation, as a portion of our national inheritance, incapable of
annihilation, so long as genius has an admirer or liberty a friend.
Mr. President: The character of Henry Clay was formed and
developed by the influence of our free institutions. His physical,
mental, and moral faculties were the gift of God. That they were

greatly superior to the faculties allotted to most men, cannot be
questioned. They were not cultivated, improved, and directed by a
liberal or collegiate education. His respectable parents were not
wealthy, and had not the means of maintaining their children at
college. Moreover, his father died when he was a boy. At an early
period, Mr. Clay was thrown upon his own resources, without
patrimony. He grew up in a clerk’s office in Richmond, Virginia. He
there studied law. He emigrated from his native state, and settled in
Lexington, Kentucky, where he commenced the practice of his
profession before he was of full age.
The road to wealth, to honour, and fame, was open before him.
Under our Constitution and laws he might freely employ his great
faculties unobstructed by legal impediments, and unaided by
exclusive privileges. Very soon Mr. Clay made a deep and favorable
impression upon the people among whom he began his career. The
excellence of his natural faculties was soon displayed. Necessity
stimulated him in their cultivation. His assiduity, skill, and fidelity in
professional engagements secured public confidence. He was elected
member of the legislature of Kentucky, in which body he served
several sessions prior to 1806. In that year he was elevated to a seat
in the senate of the United States.
At the bar and in the General Assembly of Kentucky, Mr. Clay first
manifested those high qualities as a public speaker which have
secured to him so much popular applause and admiration. His
physical and mental organization eminently qualified him to become
a great and impressive orator. His person was tall, slender, and
commanding. His temperament ardent, fearless, and full of hope. His
countenance clear, expressive, and variable—indicating the emotion
which predominated at the moment with exact similitude. His voice,
cultivated and modulated in harmony with the sentiment he desired
to express, fell upon the ear like the melody of enrapturing music.
His eye beaming with intelligence and flashing with coruscations of
genius. His gestures and attitudes graceful and natural. These
personal advantages won the prepossessions of an audience, even

before his intellectual powers began to move his hearers; and when
his strong common sense, his profound reasoning, his clear
conceptions of his subject in all its bearings, and his striking and
beautiful illustrations, united with such personal qualities, were
brought to the discussion of any question, his audience was
enraptured, convinced, and led by the orator as if enchanted by the
lyre of Orpheus.
No man was ever blessed by his Creator with faculties of a higher
order of excellence than those given to Mr. Clay. In the quickness of
his perceptions, and the rapidity with which his conclusions were
formed, he had few equals and no superior. He was eminently
endowed with a nice, discriminating taste for order, symmetry, and
beauty. He detected in a moment every thing out of place or
deficient in his room, upon his farm, in his own or the dress of
others. He was a skilful judge of the form and qualities of his
domestic animals, which he delighted to raise on his farm. I could
give you instances of the quickness and minuteness of his keen
faculty of observation which never overlooked any thing. A want of
neatness and order was offensive to him. He was particular and neat
in his handwriting and his apparel. A slovenly blot or negligence of
any sort met his condemnation; while he was so organized that he
attended to, and arranged little things to please and gratify his
natural love for neatness, order, and beauty, his great intellectual
faculties grasped all the subjects of jurisprudence and politics with a
facility amounting almost to intuition. As a lawyer, he stood at the
head of his profession. As a statesman, his stand at the head of the
Republican Whig party for nearly half a century, establishes his title
to preeminence among his illustrious associates.
Mr. Clay was deeply versed in all the springs of human action. He
had read and studied biography and history. Shortly after I left
college, I had occasion to call on him in Frankfort, where he was
attending court, and well I remember to have found him with
Plutarch’s Lives in his hands. No one better than he knew how to
avail himself of human motives, and all the circumstances which

surrounded a subject, or could present them with more force and
skill to accomplish the object of an argument.
Mr. Clay, throughout his public career, was influenced by the
loftiest patriotism. Confident in the truth of his convictions and the
purity of his purposes, he was ardent, sometimes impetuous, in the
pursuit of objects which he believed essential to the general welfare.
Those who stood in his way were thrown aside without fear or
ceremony. He never affected a courtier’s deference to men or
opinions which he thought hostile to the best interests of his
country; and hence he may have wounded the vanity of those who
thought themselves of consequence. It is certain, whatever the
cause, that at one period of his life Mr. Clay might have been
referred to as proof that there is more truth than fiction in those
profound lines of the poet—
‘He who ascends the mountain top shall find
Its loftiest peaks most wrapt in clouds and snow;
He who surpasses or subdues mankind,
Must look down on the hate of those below:
Though far above the sun of glory glow,
And far beneath the earth and ocean spread.
Round him are icy rocks, and loudly blow
Contending tempests on his naked head,
And thus reward the toils which to those summits led.’
Calumny and detraction emptied their vials upon him. But how
glorious the change! He outlived malice and envy. He lived long
enough to prove to the world that his ambition was no more than a
holy aspiration to make his country the greatest, most powerful, and
best governed on the earth. If he desired its highest office, it was

because the greater power and influence resulting from such
elevation would enable him to do more than he otherwise could for
the progress and advancement—first of his own countrymen, then of
his whole race. His sympathies embraced all. The African slave, the
Creole of Spanish America, the children of renovated classic Greece
—all families of men, without respect to color or clime, found in his
expanded bosom and comprehensive intellect a friend of their
elevation and amelioration. Such ambition as that, is God’s
implantation in the human heart for raising the down-trodden
nations of the earth, and fitting them for regenerated existence in
politics, in morals, and religion.
Bold and determined as Mr. Clay was in all his actions, he was,
nevertheless, conciliating. He did not obstinately adhere to things
impracticable. If he could not accomplish the best, he contented
himself with the nighest approach to it. He has been the great
compromiser of those political agitations and opposing opinions
which have, in the belief of thousands, at different times,
endangered the perpetuity of our Federal Government and Union.
Mr. Clay was no less remarkable for his admirable social qualities
than for his intellectual abilities. As a companion, he was the delight
of his friends; and no man ever had better or truer. They have loved
him from the beginning, and loved him to the last. His hospitable
mansion at Ashland was always open to their reception. No guest
ever thence departed without feeling happier for his visit. But, alas!
that hospitable mansion has already been converted into a house of
mourning; already has intelligence of his death passed with electric
velocity to that aged and now widowed lady, who, for more than fifty
years, bore to him all the endearing relations of wife, and whose
feeble condition prevented her from joining him in this city, and
soothing the anguish of life’s last scene by those endearing
attentions which no one can give so well as woman and a wife. May
God infuse into her heart and mind the Christian spirit of submission
under her bereavement! It cannot be long before she may expect a

rëunion in Heaven. A nation condoles with her and her children on
account of their irreparable loss.
Mr. Clay, from the nature of his disease, declined very gradually.
He bore his protracted sufferings with great equanimity and
patience. On one occasion, he said to me, that when death was
inevitable and must soon come, and when the sufferer was ready to
die, he did not perceive the wisdom of praying to be ‘delivered from
sudden death.’ He thought under such circumstances the sooner
suffering was relieved by death the better. He desired the
termination of his own sufferings, while he acknowledged the duty
of patiently waiting and abiding the pleasure of God. Mr. Clay
frequently spoke to me of his hope of eternal life, founded upon the
merits of Jesus Christ as a Saviour; who, as he remarked, came into
the world to bring ‘life and immortality to light.’ He was a member of
the Episcopalian Church. In one of our conversations he told me,
that as his hour of dissolution approached, he found that his
affections were concentrating more and more upon his domestic
circle—his wife and children. In my daily visits, he was in the habit of
asking me to detail to him the transactions of the senate. This I did,
and he manifested much interest in passing occurrences. His
inquiries were less frequent as his end approached. For the week
preceding his death, he seemed to be altogether abstracted from the
concerns of the world. When he became so low that he could not
converse without being fatigued, he frequently requested those
around him to converse. He would then quietly listen. He retained
his mental faculties in great perfection. His memory remained
perfect. He frequently mentioned events and conversations of recent
occurrence, showing that he had a perfect recollection of what was
said and done. He said to me that he was grateful to God for
continuing to him the blessing of reason, which enabled him to
contemplate and reflect on his situation. He manifested during his
confinement the same characteristics which marked his conduct
through the vigor of his life. He was exceedingly averse to give his
friends ‘trouble,’ as he called it. Some time before he knew it, we
commenced waiting through the night in an adjoining room. He said

to me, after passing a painful day, ‘Perhaps some one had better
remain all night in the parlor.’ From this time he knew some friend
was constantly at hand, ready to attend to him.
Mr. President, the majestic form of Mr. Clay will no more grace
these halls. No more shall we hear that voice which has so often
thrilled and charmed the assembled representatives of the American
people. No more shall we see that waving hand and eye of light, as
when he was engaged unfolding his policy in regard to the varied
interests of our growing and mighty republican empire. His voice is
silent on earth for ever! The darkness of death has obscured the
lustre of his eye. But the memory of his services—not only to his
beloved Kentucky, not only to the United States, but for the cause of
human freedom and progress throughout the world—will live
through future ages, as a bright example, stimulating and
encouraging his own countrymen and the people of all nations in
their patriotic devotions to country and humanity.
With Christians, there is yet a nobler and a higher thought in
regard to Mr. Clay. They will think of him in connection with eternity.
They will contemplate his immortal spirit occupying its true relative
magnitude among the moral stars of glory in the presence of God.
They will think of him as having fulfilled the duties allotted to him on
earth, having been regenerated by Divine grace, and having passed
through the valley of the shadow of death, and reached an
everlasting and happy home in that ‘house not made with hands,
eternal in the heavens.’
On Sunday morning last I was watching alone at Mr. Clay’s
bedside. For the last hour he had been unusually quiet, and
I thought he was sleeping. In that, however, he told me I was
mistaken. Opening his eyes and looking at me, he said,
‘Mr. Underwood, there may be some question where my remains
shall be buried. Some persons may designate Frankfort. I wish to
repose at the cemetery in Lexington, where many of my friends and

connections are buried.’ My reply was, ‘I will endeavor to have your
wish executed.’
I now ask the senate to have his corpse transmitted to
Lexington, Kentucky, for sepulture. Let him sleep with the dead of
that city, in and near which his home has been for more than half a
century. For the people of Lexington, the living and the dead, he
manifested, by the statement made to me, a pure and holy
sympathy, and a desire to cleave unto them, as strong as that which
bound Ruth to Naomi. It was his anxious wish to return to them
before he died, and to realize what the daughter of Moab so strongly
felt and beautifully expressed: ‘Thy people shall be my people, and
thy God my God. Where thou diest will I die, and there will I be
buried.’
It is fit that the tomb of Henry Clay should be in the city of
Lexington. In our Revolution, liberty’s first libation-blood was poured
out in a town of that name in Massachusetts. On hearing it, the
pioneers of Kentucky consecrated the name, and applied it to the
place where Mr. Clay desired to be buried. The associations
connected with the name harmonize with his character; and the
monument erected to his memory at the spot selected by him will be
visited by the votaries of genius and liberty with that reverence
which is inspired at the tomb of Washington. Upon that monument
let his epitaph be engraved.
Mr. President, I have availed myself of Doctor Johnson’s
paraphrase of the epitaph on Thomas Hanmer, with a few alterations
and additions, to express in borrowed verse my admiration for the
life and character of Mr. Clay, and with this heart-tribute to the
memory of my illustrious colleague I conclude my remarks:

Born when Freedom her stripes and stars unfurl’d,
When Revolution shook the startled world—
Heroes and sages taught his brilliant mind
To know and love the rights of all mankind.
‘In life’s first bloom his public toils began,
At once commenced the senator and man:
In business dext’rous, weighty in debate,
Near fifty years he labor’d for the state.
In every speech persuasive wisdom flow’d,
In every act refulgent virtue glow’d;
Suspended faction ceased from rage and strife,
To hear his eloquence and praise his life.
Resistless merit fixed the Members’ choice,
Who hail’d him Speaker with united voice.’
His talents ripening with advancing years—
His wisdom growing with his public cares—
A chosen envoy, war’s dark horrors cease,
And tides of carnage turn to streams of peace.
Conflicting principles; internal strife,
Tariff and slavery, disunion rife,
All, all are compromised by his great hand,
And beams of joy illuminate the land.
Patriot, Christian, Husband, Father, Friend,

Thy work of life achieved a glorious end!
I offer the following resolutions:
Resolved, That a committee of six be appointed by the president of the
senate, to take order for superintending the funeral of Henry Clay, late a member
of this body, which will take place to-morrow at twelve o’clock, M., and that the
senate will attend the same.
Resolved, That the members of the senate, from a sincere desire of showing
every mark of respect to the memory of the deceased, will go into mourning for
one month by the usual mode of wearing crape on the left arm.
Resolved, As a further mark of respect entertained by the senate for the
memory of Henry Clay, and his long and distinguished services to his country, that
his remains, in pursuance of the known wishes of his family, be removed to the
place of sepulture selected by himself at Lexington, in Kentucky, in charge of the
sergeant at arms, and attended by a committee of six senators, to be appointed
by the president of the senate, who shall have full power to carry this resolution
into effect.
Mr. CASS.—Mr. President: Again has an impressive warning come
to teach us, that in the midst of life we are in death. The ordinary
labors of this hall are suspended, and its contentions hushed, before
the power of Him, who says to the storm of human passion, as He
said of old to the waves of Galilee, PEACE, BE STILL. The lessons of His
providence, severe as they may be, often become merciful
dispensations, like that which is now spreading sorrow through the
land, and which is reminding us that we have higher duties to fulfil,
and graver responsibilities to encounter, than those that meet us
here, when we lay our hand upon His holy word, and invoke His holy
name, promising to be faithful to that Constitution, which He gave
us in His mercy, and will withdraw only in the hour of our blindness
and disobedience, and of His own wrath.
Another great man has fallen in our land, ripe indeed in years
and in honors, but never dearer to the American people than when

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