Professional Documents
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Facility Layout
Facility Layout
Layout
Logistics Process
Production Plant Layout (3)
Goals (examples):
minimal material handling costs
minimal investments
minimal throughput time
flexibility
efficient use of space
Production Plant Layout (4)
Restrictions:
legislation on employees working
conditions
present building (columns/waterworks)
Methods:
Immer: The right equipment at the right
place to permit effective processing
Apple: Short distances and short times
Goals Production Plant Layout
Plan for the preferred situation in the future
Selection 10 Evaluation
0 - Data gathering (1)
Source: product design
product design
BOM
drawings
gozinto (assembly) chart, see fig 2.10
redesign, standardization simplifications
0 - Data gathering (2)
Source: Process design
make/buy
equipment used
process times
operations process chart (fig 2.12)
R S
P = receiving
S = shipping
long line
R
Layout
volumes of production
layout type
variety of products
product variety
Layout determines
material handling
utilization of space, equipment and
personnel (table 2.2)
Second department:
X-relation last placed department
A-relation with first. If none E-relation
with first, etcetera
CORELAP step 2
Weighted placement value
8 7 6
1 1st 5
2nd
2 3 4
4 - Space requirements
Building geometry or building site
space available
Desired production rate, distinguish:
Engineer to order (ETO)
Production to order (PTO)
Production to stock (PTS)
marketing forecast productions quantities
4 - Space requirements
Equipment requirements:
Production rate number of machines
required
Employee requirements
1. Production center
for manufacturing areas
machinespace requirements
2. Converting
e.g. for storage areas
present space requirement space
requirements
non-linear function of production quantitiy
4 - Space determination (2)
4. Space standards
standards
5. Ratio trend and projection
sp ace e.g. direct labour hour, unit produced
fa c to r
Not accurate!
Include space for:
packaging, storage, maintenance, offices, aisles,
inspection, receiving and shipping, canteen, tool
rooms, lavatories, offices, parking
Deterministic approach (1)
a t
n '
a b
n = # machines per operator (non-integer)
a = concurrent activity time
t = machine activity time
b= operator
Deterministic approach (2)
a t
Tc
m a b
Tc = cycle time
a = concurrent activity time
t = machine activity time
b = operator activity time
m = # machines per operator
Deterministic approach (3)
Tc
T C ( m ) C 1 m C 2
m
TC(m) = cost per unit produced as a function of m
C1 = cost per operator-hour
C2 = cost per machine-hour
Different shapes
9 Layout alternatives
Alternative layouts by shifting the
departments to other locations
6 Space relationship
diagram
Search
7 Reasons to 8 Restrictions
modify
9 Layout alternatives
Selection 10 Evaluation
Systematic Layout Planning
0 Data gathering
1 Flow 2 Activities
Analysis
3 Relationship
4 Space diagram 5 Space
requirements available
6a Space relationship
diagram 6b Analytical analyses
Search
7 Reasons to 8 Restrictions
modify
9 Layout alternatives
Selection 10 Evaluation
Automatic Guided Vehicles (AGVs)
Unmanned vehicle for in-plant transportation on
manufacturing and assembly areas
6x
4x LP-problem
(i.e. a classical TP)
5x
Operational transportation control
Job control
(routing and scheduling of transportation tasks)
Traffic control
Traffic rules
Goal: minimize empty travel + waiting time
2 options:
determine optimal route each time a new task
arrives
problem: a task may stay at the end of the route
Periodic control
time horizon (length?)
Combination 3
Separated/think-ahead (2)
Centralized control
b. with time horizons
Simulated annealing
machine 1
loaded trip
machine 2
empty trip
machine 3
machine 1
loaded trip
machine 2
empty trip
machine 3
machine 1
loaded trip
machine 2
empty trip
machine 3
Combination 4
Integrated/think-ahead
AGVs ~ parallel machines
empty travel time ~ change-over time
transportation time ~ machine time
Shop-floor scheduling
Basic concept
Case study