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10 Facility Layout-Process - PKB
10 Facility Layout-Process - PKB
Process Layout
Facility Layout
a new layout for an existing production plant, a layout for a new production plant,
etc.
Facility Layout
Facility layout can be defined as the process by which the placement of departments, workgroups within departments, workstations, machines, and stock-holding points within a facility are determined.
Facility Layout
Reduce congestion that impedes movement of people or material Minimize material handling costs Provide safety and comfort to employees Utilize labour efficiently Increase morale Utilize available space effectively and efficiently Provide ease of supervision Facilitate co-ordination and face-to-face communication Minimize investment in equipment Minimize production time Maintain flexibility of arrangement and operation
Product or Line Layouts - uses standardized processing operations to achieve smooth, high-volume flow Process or Functional Layouts - can handle varied processing requirements Project or Fixed-Position - the product or project remains stationary, and workers, materials, and equipment are moved as needed Cellular Layouts Combination Layouts
Given The flow (number of moves) to and from all departments The cost of moving from one department to another The existing or planned physical layout of the plant Determine The best locations for each department, where best means maximizing flow, while minimizing costs
F
3
Numerical flow of items between workcentres Can be impractical to obtain Does not account for the qualitative factors that may be crucial to the placement decision Systematic Layout Planning Accounts for the importance of having each department located next to every other department Is also guided by trial and error Switching workcentres then checking the results of the closeness score
1. Flow of Materials
2. Activity Relationships
Muthers
Systematic Layout
5. Space Requirement
3. Relationship Chart
4. Relationship Diagram
6. Space Available
Planning
11. Evaluation
5 U -A 1,6 X 1 X 1
300 that here the X (2) Toy Dept. and the100 (5) 1 Candy Dept. are 100 given a high rating of A.
5
6
A
E I O U X
Absolutely necessary
Especially important Important Ordinary closeness OK Unimportant Undesirable
16
8 4 2 0 -16
X
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.
3 4
(100) (300)
5
(100)
1
(100) 50 ft
20 ft
Initial Layout
Ignoring space and building constraints
Final Layout
Adjusted by square footage and building size
Note in the Final Layout that Depts. (1) and (5) are not both placed directly next to Dept. (2).
Construction Programmes
Computerised
(CORELAP) Automated Layout Design Programme (ALDEP) Plant Layout Analysis and Evaluation Technique (PLANET)
Improvement Programmes
Computerised
Operations required to produce a particular family (group) of parts are arranged in the sequence required to make that family Used when the operations system must handle a moderate variety of products in moderate volumes
Equipment can be less general-purpose Material handling costs are reduced Training periods for operators are shortened In-process inventory is lower Parts can be made faster and shipped more quickly
Equipment can be less special-purpose Changeovers are simplified Production is easier to automate
M Grinding
Assembly A A A
L Cell 1
M
Cell 2 M
G A
Assembly area
Receiving
L Cell 3
Shipping
Machine 4
Cell Formation Decision Which machines are assigned to manufacturing cells Which parts will be produced in each cell
Fundamental Requirements for Parts to be Made in Cells Demand for the parts must be high enough and stable enough that moderate batch sizes of the parts can be produced periodically. Parts must be capable of being grouped into parts families.
Cell Formulation Maxx produces superchargers for high performance cars and trucks. Maxx has implemented a group technology program in its shop and now must formulate the manufacturing cells. Maxx has identified six parts that meet the requirements for CM. The parts-machines matrix on the next slide identifies the 6 parts and 5 machines on which the parts are presently produced.
Machines
3 X X
5 X X
6 X X
Machines
X X
X X X
X X X
3 X X
5 X X
6* X X
Machines
X X
X X X
X X
* exceptional part
Parts
1 2 X X X 3 4 5 6 7 X 8
C D E F G H I
X
X X X X X X X X
X
X X X X
Parts
3 X X 5 X X 8 X 1 4 2 6* 7
F D G I A E H
X
X X X X X X X X
X X X X
3 manufacturing cells (MC1, MC2, MC3) will be used. Parts 3, 5 and 8 will be produced in MC1 on machines B, C and F. Parts 1, and 4 will be produced in MC2 on machines D, G and I. Parts 2, 6 and 7 will be produced in MC3 on machines A, E and H. Part 6 is an exceptional part that cannot be produced within a single cell. A second machine F needs to be purchased or else it needs to be moved between MC1 and MC3.