Facility Layout

What is Facility Layout?

Location or arrangement of everything within & around an existing or proposed facility Objective: Efficient flow of work, material, people and information through the system.

Minimize movement and material handling costs Eliminate wasted or redundant movement

Reduce manufacturing cycle time and customer service time.

Facilitate communication and interaction between customer and other involved in production Promote product and service quality

Provide flexibility to adept to changing conditions

Types of Layouts: Basic layouts

Process Layout or Functional Layouts: Group similar activities
together in departments or work centers according to the process or function they perform.

Product Layouts Arrange activities in a line according to the

sequence of operations that need to be performed to assemble a particular product.

Fixed-position In this layout, the product remains stationary for the entire manufacturing cycle. Equipment, workers, materials and other resources are brought to the production site.

Process Layout in Manufacturing

Lathe Department Milling Department Drilling Department

L L L L L

L L L L L

G G

G G
Grinding Department Receiving and Shipping

G G

P P
Painting Department

A
Assembly

Process Layout
Lathe Warehouse Lathe Mill Mill

Lathe

Drill
Drill Grind Grind

Weld Paint Assembly Assembly

Weld

Lathe Mill Mill

Paint

Warehouse

Process Layout in Services

Womens dresses Shoes Housewares

Womens dresses

Cosmetics and jewelry

Childrens department

Womens sportswear

Entry and display area

Mens department

Types of Layouts: Basic layouts

Process Layout or Functional Layouts: Group similar activities
together in departments or work centers according to the process or function they perform.

Product Layouts Arrange activities in a line according to the

sequence of operations that need to be performed to assemble a particular product.

Fixed-position In this layout, the product remains stationary for the entire manufacturing cycle. Equipment, workers, materials and other resources are brought to the production site.

A Product Layout
In

Out

Product Layout
Lathe Warehouse Press Mill Lathe

Drill
Bend Drill

Grind Drill

Drill

Lathe

Drill

Assembly

Comparison of Product and Process Layouts

Product
Description Sequential arrangement of activities Continuous, mass production, mainly assembly

Process

Type of process

Product Demand Volume Equipment

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

Comparison of Product and Process Layouts

Product
Workers Inventory Limited skills Low in-process, high finished goods Storage space Small Material handling Fixed path (conveyor) aisle Narrow (passageway) Scheduling Part of balancing Layout decision Line balancing Goal Equalize work at each station Advantage Efficiency

Process
Varied skills High in-process, low finished goods Large Variable path (forklift) Wide Dynamic Machine location Minimize material handling cost Flexibility

Types of Layouts: Basic layouts

Process Layout or Functional Layouts: Group similar activities
together in departments or work centers according to the process or function they perform.

Product Layouts Arrange activities in a line according to the

sequence of operations that need to be performed to assemble a particular product.

Fixed-position In this layout, the product remains stationary for the entire manufacturing cycle. Equipment, workers, materials and other resources are brought to the production site.

Fixed-Position Layouts

Fixed Position Layout

Lathe Warehouse Press Grind Warehouse Drill Paint

Assembly

Fixed-Position Layouts
Typical of projects Equipment, workers, materials, other resources brought to the site Highly skilled labor Often low fixed Typically high variable costs

Product Layout - Advantages

Since the layout corresponds to the sequence of operations, smooth and logical flow lines result Since the work from one process is fed directly into the next, small in-process inventories result Total production time per unit is short Since the machines are located as to minimize distances between consecutive operations, material handling is reduced Little skill is usually required by operators at the production line; hence, training is simple, short and inexpensive Simple production planning and control systems are possible Less space is occupied by work in transit and for temporary storage

Lower variable cost per unit

Product Layout - Limitations

A breakdown of one machine may lead to complete stoppage of the line that follows that machine Since the layout is determined by the product, a change in product design may require major alterations in the layout The pace of production is determined by the slowest machine

Supervision is general
Comparatively high investment is required, as identical machines (a few not fully utilized) are sometimes distributed along the line Lack of flexibility

Fixed-Position Layout - Advantages

Material movement is reduced Promotes job enlargement by allowing individuals or teams the perform whole job

Continuity of operations and responsibility results from team

High flexibility; can accommodate changes in product design, product mix, and production volume Independent of production centers allows scheduling to achieve minimum total production time

Fixed-Position Layout - Limitations

Increased movement of personnel and equipment Equipment duplication may occur Higher skill requirements for personnel General supervision required Cumbersome and costly positioning of material and machinery

Low equipment utilization

Process Layout - Advantages

Better utilization of machines Fewer machines required High degree of flexibility relative to equipment or manpower allocation for specific tasks Comparatively low investment in machines is required The diversity of the task offers a more interesting and satisfying occupation for the operator Specialized supervision is possible

Process Layout - Limitations

Since longer flow lines usually result, material handling is more expensive Production planning and control systems are more involved Total production time is usually longer Comparatively large amounts of in-process inventory results Space and capital are tied up by work-in-process Because of the diversity of the jobs in specialized departments, higher grades of skill are required

Types of Layouts
High Product Layout

Medium

Group Technology / Cellular Layout

Fixed Location Layout Low Medium Process Layout High

Low

Variety

Designing Process Layouts

Goal: minimize material handling costs Block Diagramming
minimize nonadjacent loads use when quantitative data is available

Relationship Diagramming
based on location preference between areas use when quantitative data is not available

Block Diagramming
STEPS create load summary chart quantity in which material is normally calculate composite (two moved way) movements develop trial layouts Nonadjacent load minimizing number of distance farther nonadjacent loads than the next block

Unit load

What is Block Diagramming?

Block diagramming is one way to visualize the amount of movement that occurs between departments.

Each block represents one department of a facility. Blocks can be moved around in order to minimize the distance traveled between them.

Example of Block Diagramming

Step 1: Gather Information (Department Size)
Department
1 2 3 4 5 6

Area Needed (ft2)

1000 950 750 1200 800 700

Total

5400

Example of Block Diagramming (cont.)

Step 1: Gather Information (Initial Layout)

3
60

6
90

Example of Block Diagramming (cont.)

Step 1: Gather Information (Trips between departments shown in interdepartmental flow matrix)
Department 1 2 3 4 5 6 1 -2 20 -10 -15 -70 --3 4 20 75 90 5 6 80

Example of Block Diagramming (cont.)

Step 2: Develop a block plan (Show initial traffic)
10 90

2
75

4
70 20

15

6
20

5
80

Example of Block Diagramming (cont.)

Step 2: Develop a block plan (Show new traffic)
5
75 20 70

4
20

15

3
90

1
10

80

Example of Block Diagramming (cont.)

Step 2: Develop a block plan (Show new layout) 5 4 3
60

2
90

Block Diagramming: Example 2

Load Summary Chart
1 2 3 FROM/TO DEPARTMENT

Department 1 1 2 3 4 5
60

2 100
100

3 50 200
50

4
50 40

50 60

Block Diagramming: Example (cont.)

2 2 1 1 4 3 2 3 1 1 3 4 3 2 5 5 5 4 4 5 200 loads 150 loads 110 loads 100 loads 60 loads 50 loads 50 loads 40 loads 0 loads 0 loads

Nonadjacent Loads: 110+40=150 0

110 100

150 200

3 4

4
2 Grid 1

150 200 50 50 40 60 50 110 50 60

3 5

40

Block Diagramming: Example (cont.)

(a) Initial block diagram (b) Final block diagram

1
2

Strengths
With correct information, layout efficiency can be improved. Some computer programs can quickly determine optimal solutions.

Weaknesses
Sometimes, the data is hard to gather or quantify. Sometimes it is hard to give proper weight to qualitative factors. With many nodes, it is harder to determine optimal solutions.

Relationship Diagramming

Schematic diagram that uses weighted lines to denote location preference Muthers grid
format for displaying manager preferences for department locations

Relationship A Absolutely necessary E Especially important I Important Diagramming: Example

Production O Okay U Unimportant X Undesirable

O
Offices

A U I O A U X U E A

Stockroom Shipping and receiving Locker room

U
O O

Toolroom

Relationship Diagrams: Example (cont.)

(a) Relationship diagram of original layout

Offices

Locker room

Shipping and receiving

Stockroom

Toolroom

Key: A E I Production O U X

Relationship Diagrams: Example (cont.)

(b) Relationship diagram of revised layout

Stockroom

Offices

Shipping and receiving

Toolroom

Production

Locker room

Key: A E I O U X

Systematic Layout Planning

Layout
Input Data and Activities Analysis 1. Flow of Materials 2. Activity Relationships

3. Relationship Diagram

4. Space Requirements

5. Space Available

6. Space Relationship Diagram Search

7. Modifying Considerations

8. Practical Limitations

9. Develop Layout Alternatives

10. Evaluation

Selection

Systematic Layout Planning

Systematic Layout Planning

Systematic Layout Planning

Types of Layouts
Product - seeks the best personnel and machine use in repetitive or continuous production Fixed-position - large bulky projects such as ships and buildings Group Technology / Cellular product families Process - deals with low-volume, high-variety production (job shop, intermittent production)

Office - positions workers, their equipment, and spaces/offices to provide for movement of information Retail - allocates shelf space and responds to customer behavior Warehouse - addresses trade-offs between space and material handling

Systematic Layout Planning

Computerized layout Solutions

CRAFT

Computerized Relative Allocation of Facilities Technique Computerized Relationship Layout Planning visual feedback allow user to quickly test a variety of scenarios

CORELAP

PROMODEL and EXTEND

Three-D modeling and CAD

integrated layout analysis available in VisFactory and similar software

Designing Service Layouts

Must be both attractive and functional Types Free flow layouts

encourage browsing, increase impulse purchasing, are flexible and visually appealing encourage customer familiarity, are low cost, easy to clean and secure, and good for repeat customers both increase customer sightlines and exposure to products, while encouraging customer to circulate through the entire store

Grid layouts

Loop and Spine layouts

Types of Store Layouts

Designing Product Layouts

Objective

Balance the assembly line

tries to equalize the amount of work at each workstation physical restrictions on the order in which operations are performed maximum amount of time a product is allowed to spend at each workstation

Line balancing

Precedence requirements

Cycle time

Cycle Time Example

production time available desired units of output

Cd = Cd =

(8 hours x 60 minutes / hour) (120 units)

Cd =

480 120

= 4 minutes

Flow Time vs Cycle Time

Cycle time = max time spent at any station Flow time = time to complete all stations
1
4 minutes

2
4 minutes

3
4 minutes

Flow time = 4 + 4 + 4 = 12 minutes Cycle time = max (4, 4, 4) = 4 minutes

Efficiency of Line
Efficiency Minimum number of workstations

t
E = nC a
where
i=1

t
N=
i=1

Cd

ti j n Ca Cd

= completion time for element i = number of work elements = actual number of workstations = actual cycle time = desired cycle time

Line Balancing Procedure

1. Draw and label a precedence diagram 2. Calculate desired cycle time required for the line 3. Calculate theoretical minimum number of workstations 4. Group elements into workstations, recognizing cycle time and precedence constraints 5. Calculate efficiency of the line 6. Determine if the theoretical minimum number of workstations or an acceptable efficiency level has been reached. If not, go back to step 4.

Line Balancing: Example

WORK ELEMENT A B C D Press out sheet of fruit Cut into strips Outline fun shapes Roll up and package 0.2 PRECEDENCE A A B, C TIME (MIN) 0.1 0.2 0.4 0.3

B
0.1 A

D 0.3 C

0.4

Line Balancing: Example (cont.)

WORK ELEMENT A B C D Press out sheet of fruit Cut into strips Outline fun shapes Roll up and package PRECEDENCE A A B, C TIME (MIN) 0.1 0.2 0.4 0.3

40 hours x 60 minutes / hour 2400 Cd = = = 0.4 minute 6,000 units 6000 0.1 + 0.2 + 0.3 + 0.4 1.0 N= = = 2.5 3 workstations 0.4 0.4

Line Balancing: Example (cont.)

WORKSTATION 1 2 3 ELEMENT A B C D 0.2

REMAINING TIME
0.3 0.1 0.0 0.1

REMAINING ELEMENTS
B, C C, D D none Cd = 0.4 N = 2.5

B
0.1 A

D 0.3 C

0.4

Line Balancing: Example (cont.)

Work station 1 Work station 2 Work station 3

Cd = 0.4 N = 2.5

A, B
0.3 minute

C
0.4 minute

D
0.3 minute

1.0 0.1 + 0.2 + 0.3 + 0.4 E= = = 0.833 = 83.3% 1.2 3(0.4)

Computerized Line Balancing

Use heuristics to assign tasks to workstations
Longest operation time Shortest operation time Most number of following tasks Least number of following tasks Ranked positional weight

Hybrids Layouts
Cellular layouts

group dissimilar machines into work centers (called cells) that process families of parts with similar shapes or processing requirements
automated machining and material handling systems which can produce an enormous variety of items processes more than one product model in one line

Flexible manufacturing system

Mixed-model assembly line

Cellular Layouts
1. Identify families of parts with similar flow paths 2. Group machines into cells based on part families 3. Arrange cells so material movement is minimized 4. Locate large shared machines at point of use

Parts Families

A family of similar parts

A family of related grocery items

Original Process Layout

Assembly

5 2 1 3 10

8
12 11

Raw materials

Part Routing Matrix

Parts A B C D E F G H
Figure 5.8

1 x

2 x

Machines 4 5 6 7 x x x x x x x x

8 9 10 11 12 x x x x x x x x x

x x x x

x
x

x
x

x x

Revised Cellular Layout

Assembly

10

12

11
4 Cell 1 Cell 2 6 Cell 3 7 2 1 3 5

A B C Raw materials

Reordered Routing Matrix

Parts 1 2 4 Machines 8 10 3 6 9 5 7 11 12

A D F C G B H E

x x x

x x

x x x

x x x x x
x x x x x x x x x x x x x x x

A Manufacturing Cell with Worker Paths

Source: J.T. Black, Cellular Manufacturing Systems Reduce Setup Time, Make Small Lot Production Economical. Industrial Engineering (November 1983).

Direction of part movement within cell HM VM

Worker 3

VM

L
Paths of three workers moving within cell
Worker 2

Material movement Key: S L HM VM G = Saw = Lathe = Horizontal milling machine = Vertical milling machine = Grinder

L
Final inspection

Worker 1

Finished part

In

Out

Cellular Manufacturing (CM)

Product layouts (assembly lines, mass production one a few products on the same line) is the most efficient of the basic layout options Many products are not made in volumes that require a product layout Cellular manufacturing (group technology) forms families of products that have common production requirements Locate machines, people, jigs, fixtures, drawings, measuring equipment, material handling equipment together (focused factory)

Cellular Manufacturing
The cellular approach is to organize the entire manufacturing process for particular or similar products into one group of team members and machines known as a "Cell". These "cells" are arranged in a U-shaped layout to easily facilitate a variety of operations.

Parts or assemblies move one at a time (or in small batch sizes).

The parts are handed off from operation to operation without opportunity to build up between operations.

Cellular Manufacturing
Fast setup and quick changeovers are essential to Cellular Manufacturing systems since production runs are shorter. Setup reduction principles are used to achieve one piece flow and mixed model synchronization. All cells concentrate on eliminating waste.

Benefits of CM
Common tooling required for many products (fewer setups) Tooling can be justified since many products require it (more volume when products are grouped) Minimized material handling Simple production schedule Short cycle time, Low WIP Cross-training employees operate several machines Minimized material handling costs since no paperwork is required and distance is small Employees accept more responsibility of supervision (scheduling of parts within cell, scheduling of vacation, purchasing of material, managing a budget) Simple flow pattern and reduced paperwork Buffers are small if batch size is small

Family Formation
Various levels macro and micro Macro entire factories (focused factories) can specialize in a particular type of part Micro families can be based on similarities in part geometry (group shafts, flat parts, gears, etc), process requirements (castings, forgings, sheet metal parts, heattreated parts, printed circuit boards) How are these groupings determined?

Finding Part Families

Production Flow Analysis : Since the parts in a part family have similar manufacturing processes, it is possible to identify similar parts by studying the route sheets.

Parts with similar routes can be grouped into families.

Group Analysis
To create part families and machine groups a part-machine matrix is created. This is a 0-1 matrix in which a one signifies that a machine is required for a given part. While creating this matrix the machine refers to a "type" of machine. Thus, if there are 5 identical CNC lathes we will create one row in the matrix for these lathes.

Also, the number of times a part visits a machine is not considered at this stage

Group Analysis
Once a the part-machine matrix is created, it is customary to remove approximately 10% of the most heavily used machines. Several copies of these machines are likely to be available and thus it is always possible to split these machines between different groups later. The remaining matrix is then inspected for part families.

Group Analysis
To identify the part-families the rows and columns are interchanged such that a block-diagonal structure is obtained. There are several algorithms that can be used to do this. A simple algorithm for this problem can be described as follows:

Pick any row and draw a horizontal line through it. For each 1 in the row that has been crossed once draw a vertical line through the corresponding column.

Pick each new column identified in the previous step. For each 1 in the column that has been crossed once draw a horizontal line through the row.
Repeat this process until there are no singly-crossed 1s in the matrix.

Remove the rows and columns that have been crossed to form a part family-machine group.
Continue for the rest of the matrix

Group Analysis

Problem 2
A B C D E F

1
2 3 4

1
1 1 0

0
1 0 1

0
0 1 0

1
0 0 0

0
1 0 1

1
0 1 0

5
6

0
0

0
0

1
0

1
0

0
0

0
0

1
2 3 4

1
1 1 0

0
1 0 1

0
0 1 0

1
0 0 0

0
1 0 1

1
0 1 0

5
6

0
0

0
0

1
0

1
0

0
0

0
0

1
2 3 4

1
1 1 0

0
1 0 1

0
0 1 0

1
0 0 0

0
1 0 1

1
0 1 0

5
6

0
0

0
0

1
0

1
0

0
0

0
0

1
2 3 4

1
1 1 0

0
1 0 1

0
0 1 0

1
0 0 0

0
1 0 1

1
0 1 0

5
6

0
0

0
0

1
0

1
0

0
0

0
0

1
2 3 4

1
1 1 0

0
1 0 1

0
0 1 0

1
0 0 0

0
1 0 1

1
0 1 0

5
6

0
0

0
0

1
0

1
0

0
0

0
0

Thus all parts require all machines and only cell is formed

Automated Manufacturing Cell

Source: J. T. Black, Cellular Manufacturing Systems Reduce Setup Time, Make Small Lot Production Economical. Industrial Engineering (November 1983)

Advantages and Disadvantages of Cellular Layouts

Advantages

Disadvantages

Reduced material handling and transit time Reduced setup time Reduced work-inprocess inventory Better use of human resources Easier to control Easier to automate

Inadequate part families Poorly balanced cells Expanded training and scheduling of workers Increased capital investment

Flexible Manufacturing Systems (FMS)

FMS consists of numerous programmable machine tools connected by an automated material handling system and controlled by a common computer network FMS combines flexibility with efficiency FMS layouts differ based on

variety of parts that the system can process size of parts processed average processing time required for part completion

Full-Blown FMS

Mixed Model Assembly Lines

Produce multiple models in any order on one assembly line Issues in mixed model lines
Line balancing U-shaped line Flexible workforce Model sequencing

Balancing U-Shaped Lines

Precedence diagram:

Cycle time = 12 min

(a) Balanced for a straight line

A,B C,D E

(b) Balanced for a U-shaped line

A,B

9 min Efficiency =

12 min

3 min
C,D

24 24 = = .6666 = 66.7 % 3(12) 36

Efficiency =

24 24 = = 100 % 12 min 2(12) 24

12 min