Departemen Teknik Industri

FACILITY LAYOUT

Lecture-04
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OUTLINE
• Facility layout: [Using Quantitative
Measures]
• Facility layout: [Using Quantitative and
Qualitative Measures]
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FLOW PROCESSES
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Layout Evaluation Criteria

• The most commonly used quantitative
criterion for evaluating layout:
M M
TC  TCMF  TCtran    fij hij dij
i 1 j 1

• TCMF :Total Cost of Material Flow per time period

• TCtran: Total Cost of Material Transport per time
period
• TC : Total Cost of Material Movement per time
period
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Total Cost of Material Movement

• M: number of activities (facilities)
• fij : flow volume between activities i and j,
measured per time period
• dij: distance between activities i and j,
measured per time period
• hij: cost per move between activities i and
j per unit distance
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FACILITY LAYOUT
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FACILITY LOCATION
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FACILITY LAYOUT
• Machine Layout
• Department Layout
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Machine Layout
• Relationship between activities:
 Quantitative measures (Flow of materials)
• Other quantitative and qualitative measures are
possible (e.g. adjacency)
• Flow Requirements
 Unit load (batch) sizes
 Equivalence Factors
• Machine Layout Criterion
 Total weighted distance
 Total cost
 Combination of Quantitative and Qualitative Criteria.
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FLOW WITHIN DEPARTMENTS

• Depends on the type of machine layout
• Fixed Product Layout
• Product Layout
 Most flow is between adjacent machines.
 Depends on whether or not operators are
shared between machines (end-to-end, front-
to-front, U-shaped flow pattern, etc.)
• Group Layout
 Little flow between groups
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FLOW WITHIN DEPARTMENTS

• Process Layout
 Variable-path material handling
 Most flow is between machines
 Flow pattern depends on machine-aisle
arrangement (Two-way aisles; One-way aisles)
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QAP Model of Machine Layout

• Machine layout can be modelled as a
Quadratic Assignment Problem (QAP)
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QAP
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Example:[4 Sites & 4 Facilities]

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QAP
• The layout models are NP-complete
• Optimal algorithms: Branch and bound,
Decomposition, Cutting plane algorithms
• These algorithms can produce optimal solutions
for only small sized problem (M<=20)
• Since it is computationally infeasible to find an
optimal solution when M>20.
• Heuristic (non-optimal) procedures are typically
used to solve QAP’s
• Steepest Descent Pairwise Interchange (SDPI)
Heuristic
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Steepest Descent
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SLP
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Qualitative Relationships
• Material Flow
• Personnel Flow
• Same resource
• Same personnel
• Communication
• Safety
• Noise
• Structural
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Systematic Layout Planning

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RELATIONSHIP DIAGRAMMING FOR NEW

LAYOUTS
• Step-1: Select the first department to enter the
layout (The Dept with the greatest number of
“A”)
• Step-2:Select the second department to enter
the layout (The Dept selected should have an “A”
relationship with the first Dept.)
• Step-3:Select the third department to enter the
layout (The third Dept selected should have the
highest combined relationship with the two
Depts)
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RELATIONSHIP DIAGRAMMING FOR NEW

LAYOUTS
• Step-4:Select the fourth department to enter the
layout (The same logic as in Step-3)
• Step-n:Department n is placed according to the
rules described in Steps 3 and 4.
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Systematic Layout Planning

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Systematic Layout Planning

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Systematic Layout Planning

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Department Layout
• Manufacturing Departments
 A group of machines and/or workstations
• Non-Manufacturing Departments
 Shipping/Receiving areas, Storage areas,
Offices, Cafeterias, etc.
• Flow Pattern between Departments
 U-shaped, S-Shaped, W-Shaped.
• Block Layout Representations
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Block Layout Representations

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Non-Manufacturing Departments
• Offices –offices for administrative, support, and
engineering staff; meeting/conference rooms;
etc.
• Storage/Warehousing –dedicated areas outsides
of each manufacturing department for the
storage of raw materials, in-process inventories,
and finished goods.
• Shipping/Receiving –dockboard area, manuvering
area for MHE used for loading/unloading,
buffer/staging areas, container and trash storage,
offices and trucker’s lounge.
• Restrooms –located within 200 feet of every
permanent workstation.
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Non-Manufacturing Departments
• Food Services
• Health Services, looker rooms, and wash
rooms.
• Plant Services –HVAC, pump, generators,
etc.
• Emergency exits –an exit must be within
150 ft of any point in the building.
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Total Facility
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Total Site