Professional Documents
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Facility Layout
Facility Layout
Facility Layout
OBJECTIVES
Process Layout
Layout Planning
Service Layout
Facility Layout
Defined
Facility layout can be defined as the process by which the
placement
of
departments,
workgroups
within
departments, workstations, machines, and stockholding points within a facility are determined
This process requires the following inputs:
Specification of objectives of the system in terms of output
and flexibility
Estimation of product or service demand on the system
Processing requirements in terms of number of operations
and amount of flow between departments and work centers
Space requirements for the elements in the layout
Space availability within the facility itself
Machine Objectives of
Facility Layout
Arrangement of areas within a facility to:
Minimize material-handling
costs
Utilize space efficiently
Utilize labor efficiently
Eliminate bottlenecks
Facilitate communication and
interaction
Reduce manufacturing cycle
time
Reduce customer service time
Eliminate wasted or redundant
movement
Increase capacity
Fixed-Position Layout
Process Layout
Final
Inspection
Underbody
Repairs
Engine
Repairs
Oil
Replacement
Wheel
Alignment
Electrical
Repairs
Paint
Booth
Car washing
& cleaning
Office
Spare
Parts
Store
Interiors,
Door Repairs,
etc.
Dents
Repair
Work-In-Process
(WIP) Inventory is
usually high in
batch processing
Material handling is
time consuming as no
fixed route is there
Disadvantages
Maintenance cost is
low because of low
cost general purpose
machines
Advantages
Process
Layout
Routing &
scheduling is tedious
and time consuming
for different
products
High cost of supervision
because of special
treatment to every product
to be processed
The system promotes
creativity on part of
workers due to variety of
tasks performed by them
Breakdown of a machine
does not lead to halt in
production as substitute
machines are kept ready
for such situations
10
Given
Determine
11
12
13
Designing Process
Layouts
Relationship Diagramming
based on location preference between areas
use when quantitative data is not available
14
Block Diagramming
Unit load
quantity in which
material is normally
moved
Nonadjacent load
distance farther
than the next block
STEPS
create load summary chart
calculate composite (two
way) movements
develop trial layouts
minimizing number of
nonadjacent loads
15
Reason
Type of customer
Ease of supervision
Common personnel
Contact necessary
Psychology
16
Numerical
weights
Value
Closeness
Absolutely necessary
16
Especially important
Important
Ordinary closeness OK
Unimportant
Undesirable
80
17
2
I
6
1. Credit department
3
U
-U
--
2. Toy department
3. Wine department
4. Camera department
5. Candy department
Closeness rating
Letter
Note here
that the (1)
Credit Dept.
and (2) Toy
Dept. are
given a high
rating of 6.
To
4
A
4
I
1
U
--
5
U
-A
6
X
1
Note
X
Area
(sq. ft.)
100
400
300
here that
100
the 1(2) Toy Dept.
and the (5)
100
Candy Dept. are
given a high
rating of 6.
18
1
I
2
3
4
5
A
Note here again, Depts. (1) and
(2) are linked together, and
Depts. (2) and (5) are linked
together by multiple lines or
required transactions.
19
Product Layout
Difference between process and product
layout is the pattern of work flow.
Equipment or departments are dedicated to
a particular product line
Duplicate equipment is employed to avoid
backtracking, and a straight-line flow of
material movement is achievable.
Used when the batch size of a given
product or part is large relative to the no. of
different products or parts produced.
20
A Product Layout
In
Out
21
Comparison of Product
and Process Layouts
Product
Sequential
arrangement of
activities
Continuous, mass
production, mainly
assembly
Description
Type of process
Product
Demand
Volume
Equipment
Process
Functional
grouping of
activities
Intermittent, job
shop, batch
production, mainly
fabrication
Standardized, made Varied, made to
to stock
order
Stable
Fluctuating
High
Low
Special purpose
General purpose
22
Comparison of Product
and Process Layouts
Product
Limited skills
Low in-process, high
finished goods
Storage space
Small
Material handling Fixed path (conveyor)
Aisles
Narrow
Scheduling
Part of balancing
Layout decision
Line balancing
Goal
Equalize work at each
station
Advantage
Efficiency
Workers
Inventory
Process
Varied skills
High in-process, low
finished goods
Large
Variable path (forklift)
Wide
Dynamic
Machine location
Minimize material
handling cost
Flexibility
23
A high
output rate
and, thus,
low cost of
item per unit
High
efficiency of
labor &
equipment
Advantages
Product
Layout
Disadvantage
s
Inflexible to design
changes in products
or processes (the
changes in line are
usually expensive)
No need of routing or
scheduling once the
line is operational (as it
is already done during
the design of the line)
Monotonous repetitive
tasks lead to frustration
on part of workers
Breakdown of a
machine or high
absenteeism of
workers leads to halt in
production
24
Assembly line
25
Racks containing
headlight sub-assembly
Racks containing
backlight sub-assembly
Racks containing
steering wheels
sub-assembly
Workstation 1
Workstation 2
Workstation 3
Car 1
Car 2
Car 3
Conveyor
26
3
4
A single worker
5
8
27
Station 1
Station 2
Station 3
Minutes
6
7
3
per Unit
Answer: The cycle time of the line is always
determined by the work station taking the longest
time. In this problem, the cycle time of the line is 7
minutes. There is also going to be idle time at the
other two work stations.
28
Task
A
B
C
D
E
F
G
H
Time (Mins)
2
1
3.25
1.2
0.5
1
1
1.4
Description
Assemble frame
Mount switch
Assemble motor housing
Mount motor housing in frame
Attach blade
Assemble and attach safety grill
Attach cord
Test
Predecessors
None
A
None
A, C
D
E
B
F, G
29
Task Predecessors
E
D
F
E
G
B
H
E, G
B
G
H
30
1
B
1
G
3.25
1.2
.5
1.4
H
31
Max Production =
Task
A
B
C
D
E
F
G
H
Time (Mins)
2
1
3.25
1.2
0.5
1
1
1.4
Description
Assemble frame
Mount switch
Assemble motor housing
Mount motor housing in frame
Attach blade
Assemble and attach safety grill
Attach cord
Test
Predecessors
None
A
None
A, C
D
E
B
E, G
32
Cycle Time
Determine
C=
33
Answer:
Nt =
Nt =
34
35
Group Technology
(Cellular Layout):
36
111
3333
Lathe
Machines
2222
3333
1
1
1
2
2
2
2222
4444
Foundry
4444
Fitting
shop
1
1
1
2222
Paint
Shop
111
2222
3
3
3
1
1
Drilling
Machines
1
1
1
3333
4444
3333
4444
Welding
Shop
Lathe
Drilling
Fitting
Welding
Paint
111
Paint
2222
Welding
3333
Manufacturing Cell 2
2222222222
Foundry
Lathe
Fitting
Manufacturing Cell 3
3333333333
Lathe
Fitting
Drilling
Manufacturing Cell 4
444444444444444444444
Foundry
Drilling
Welding
4444
Cellular Layout
37
Cellular Layouts
1.
2.
3.
4.
38
39
Advantages and
Disadvantages
of Cellular Layouts
Advantages
Reduced material
handling and transit time
Reduced setup time
Reduced work-in- process
inventory
Better use of human
resources
Easier to control
Easier to automate
Disadvantages
40
Group Technology:
Transition from Process Layout
1. Grouping parts into families that
follow a common sequence of steps
2. Identifying dominant flow patterns
of parts families as a basis for
location or relocation of processes
3. Physically grouping machines and
processes into cells
41
42
Raw
Materials
Computer
Experts
Equipments
Assemblies
Technicians
Fuel
43
per
Ambient Conditions
Spatial Layout and Functionality
Signs,
Symbols,
and
Artifacts
44
Question Bowl
Which of the following is a process that involves
developing a relationship chart showing the
degree of importance of having each
department located adjacent to every other
department?
a.
Systematic layout planning
b.
Assembly-line balancing
c.
Splitting tasks
d.
U-shaped line layouts
e.
None of the above
45
Question Bowl
If the production time per day is 1200 minutes and
the required output per day is 500 units, which of
the following will be the required workstation
cycle time for this assembly line?
a.
2.4 minutes
b.
0.42 minutes
c.
1200 units
d.
500 units
e.
Answer: a. 2.4
minutes
(1200/500=2.4
minutes)
46
Question Bowl
You have just finished determining the cycle time
for an assembly line to be 5 minutes. The
sum of all the tasks required on this
assembly is is 60 minutes. Which of the
following is the theoretical minimum number
of workstations required to satisfy the
workstation cycle time?
a.
1 workstation
b.
5 workstations
Answer: c. 12
c.
12 workstations
workstations
d.
60 workstations
(60/5=12)
e.
None of the above
47
Question Bowl
If the sum of the task times for an assembly line is
30 minutes, the actual number of workstations
is 5, and the workstation cycle time is 10
minutes, what is the resulting efficiency of
this assembly line?
a.
0.00
b.
0.60
c.
1.00
d.
1.20
e.
Can not be computed from the data above
48
Question Bowl
Which of the following are ways that we can
accommodate a 20 second task in a 18
second cycle time?
a.
b.
c.
d.
e.
49
Question Bowl
Which of the following are ambient conditions that
should be considered in layout design?
a.
Noise level
b.
Lighting
c.
Temperature
d.
Scent
e.