Chapter 10

Facility Layout

Operations Management by R. Dan Reid & Nada R. Sanders 2nd Edition Wiley 2005
PowerPoint Presentation by R.B. Clough - UNH

Learning Objectives
   

 

Define layout planning and its importance Identify and describe different types of layouts Compare process layouts & product layouts Describe the steps involved in designing both process and product layouts Explain the advantages of hybrid layouts Define the meaning of group technology & its importance to cellular layouts

What Is Layout Planning



Layout planning is determining the best physical arrangement of resources within a facility Two broad categories of operations:
 

Intermittent processing systems Continuous processing systems

Types of Layouts


Process layouts:


Group similar resources together Designed to produce a specific product efficiently Combine aspects of both process and product layouts Product is two large to move; e.g. a building

Product layouts:


Hybrid layouts:


Fixed-Position layouts:


Process Layouts
      

General purpose & flexible resources Lower capital intensity & automation Higher labor intensity Resources have greater flexibility Processing rates are slower Material handling costs are higher Scheduling resources & work flow is more complex Space requirements are higher

Product Layouts
 

   

Specialized equipment High capital intensity & wide use of automation Processing rates are faster Material handling costs are lower Less space required for inventories Less volume or design flexibility

Hybrid Layouts


Combine elements of both product & process layouts



Maintain some of the efficiencies of product layouts Maintain some of the flexibility of process layouts Group technology & manufacturing cells Grocery stores

Examples:
 

Comparison of Product vs. Product Layouts

Process Layouts
Products: Resources: Facilities: Flexibility: Processing Rates: large #, different general purpose more labor intensive greater relative to market slower

Product Layouts
small # efficiently specialized more capital intensive lower relative to market faster

Handling costs: high Space requirements: higher

low lower

Designing Process Layouts



Step 1: Gather information:



Space needed, space available, importance of proximity between various units Using trial-and-error or decision support tools Consider exact sizes and shapes of departments and work centers including aisles and stairways Tools like drawings, 3-D models, and CAD software are available to facilitate this process

Step 2: Develop alternative block plans:



Step 3: Develop a detailed layout



Process Layout Steps



Step 1: Gather information like space needed, from-to matrix, and REL Chart for Recovery First Sports Medicine Clinic (total space 3750 sq. ft.)
A Radiology 400 sq. ft. D Examining Rooms 800 sq. ft. B Laboratory 300 sq. ft. E Surgery & Recovery 900 sq. ft. C Lobby & Waiting 300 sq. ft. F Physical Therapy 1050 sq. ft.

Step 1: Gather Information (continued)

Step 2: Develop a New Block Layout

 

Use trial and error with from-to and REL Charts as a guide Use computer software like ALDEP or CRAFT

Warehouse Layouts


Warehouse Layout Considerations:



Primary decision is where to locate each department relative to the dock Departments can be organized to minimize ld totals Departments of unequal size require modification of the typical ld calculations to include a calculation of the ratio of trips to area needed The usage of Crossdocking (see Ch.4) modifies the traditional warehouse layouts; more docks, less storage space, and less order picking

Office Layouts


Office Layout Considerations:



 

Almost half of US workforce works in an office environment Human interaction and communication are the primary factors in designing office layouts Layouts need to account for physical environment and psychological needs of the organization One key layout trade-off is between proximity and privacy Open concept offices promote understanding & trust Flexible layouts incorporating office landscaping help to solve the privacy issue in open office environments

Designing Product Layouts

   

Step 1: Step 2: Step 3: Step 4:

Identify tasks & immediate predecessors Determine the desired output rate Calculate the cycle time Compute the theoretical minimum number of workstations Step 5: Assign tasks to workstations (balance the line) Step 6: Compute efficiency, idle time & balance delay

Step 1: Identify Tasks & Immediate Predecessors

Example 10.4 Vicki's Pizzeria and the Precedence Diagram Immediate Task Time Work Element Task Description Predecessor (seconds
A B C D E F G H I Roll dough Place on cardboard backing Sprinkle cheese Spread Sauce Add pepperoni Add sausage Add mushrooms Shrinkwrap pizza Pack in box None A B C D D D E,F,G H Total task time 50 5 25 15 12 10 15 18 15 165

Layout Calculations


Step 2: Determine output rate



Vicki needs to produce 60 pizzas per hour

Step 3: Determine cycle time  The amount of time each workstation is allowed to complete its tasks

Cycle time (sec./unit) !

available time sec./day 60 min/hr x 60 sec/min ! ! 60 sec./unit desired output units/hr 60 units/hr

Limited by the bottleneck task (the longest task in a process):

available time 3600 sec./hr. ! ! 72 units/hr, or pizzas per hour bottleneck task time 50 sec./unit

Maximum output !

Layout Calculations


(continued)

Step 4: Compute the theoretical minimum number of stations



TM = number of stations needed to achieve 100% efficiency (every second is used)

task times ! TM !
cycle time
 

165 seconds ! 2.75, or 3 stations 60 sec/station

Always round up (no partial workstations) Serves as a lower bound for our analysis

Layout Calculations


(continued)

Step 5: Assign tasks to workstations



Start at the first station & choose the longest eligible task following precedence relationships Continue adding the longest eligible task that fits without going over the desired cycle time When no additional tasks can be added within the desired cycle time, begin assigning tasks to the next workstation until finished
1 Eligible task A B C D E, F, G E, F F H I Task Selected A B C D G E F H I Task time 50 5 25 15 15 12 10 18 15 Idle time 10 5 35 20 5 48 38 20 5

Workstation

Last Layout Calculation



Step 6: Compute efficiency and balance delay



Efficiency (%) is the ratio of total productive time divided by total time
Efficiency

t ! (%) !
NC

165 sec. 100 ! 91.7% 3 stations x 60 sec.

Balance delay (%) is the amount by which the line falls short of 100%
Balance delay ! 100%  91.7% ! 8.3%

Other Product Layout Considerations



Shape of the line (S, U, O, L):



Share resources, enhance communication & visibility, impact location of loading & unloading Paced lines use an automatically enforced cycle time

Paced versus un-paced lines



Single or mixed-model lines

Designing Hybrid Layouts

 

One of the most popular hybrid layouts uses Group Technology (GT) and a cellular layout GT has the advantage of bringing the efficiencies of a product layout to a process layout environment

Process Flows before the Use of GT Cells

Process Flows after the Use of GT Cells

Chapter 10 Highlights


Layout planning is deciding on the best physical arrangement of resources. There are four basic types of layouts: process, product, hybrid, and fixed position. Process layouts provide flexibility to make a variety of different products. Product layouts provide greater efficiency for one product. The steps for designing process layouts are: gather space and closeness information, develop a block plan, and develop a detailed layout.

Chapter 10 Highlights


(continued)

The steps for designing an product layout are: identify tasks and predecessors, determine output rate, determine cycle time, computing the theoretical minimum number of work stations, assigning tasks to workstations, and computing efficiency and balance delay. Hybrids layouts combine elements from both types of layouts to increase efficiency. Hybrid layouts combine GT analysis with cellular layout concepts .

The End


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