2.4 Facilities Layout Design_w3

8/10/2019 2.4 Facilities Layout Design_w3

1/34

Chapter 2Chapter 2Chapter 2Chapter 2Chapter 2Chapter 2Chapter 2Chapter 2

Thursday, September 26, 2013 Industrial Engineering 1


2/34

Facilities

Planning

Facilities

Location

StructuralDesign

Thursday, September 26,2013Industrial Engineering 2

Facilities

Design

Layout

Design

Handling SystemDesign


3/34



4/34

Developing a facilities layout is a critical stepin the facilities planning process.

Industrial engineer must be CREATIVE and

alternatives.



5/34

What is Layout : the configuration of departments, work centers,

and equipment, with particular emphasis onmovement of work (customers or materials)

through the system.

In this chapter, scope of Facilities Layout according toindustrial and manufacturing field.



6/34

1. Use workers and space efficiently2. Avoid bottlenecks among process3. Minimize production time or customer

service time



7/34



8/34

4. Minimize unnecessary material handlingcosts

5. Eliminate unnecessary movement ofworkers or materials

6. Design for safety



9/34



10/34

Inefficient operations

For Example:

High Cost

Changes in the design

of products or services

Thursday, September 26,2013 Industrial Engineering 10

Bottlenecks

The introduction of newproducts or services

Accidents

Safety hazards


11/34

Changes in

environmentalor other legal

Changes in volume ofoutput or mix of

products

Thursday, September 26,2013 Industrial Engineering 11

Changes in methodsand equipment

Morale problems


12/34


13/34

Layout design is effected by:

Centralized vs. Decentralize Storage ofWIP, Tooling, & Supplies

Fixed Path vs. Variable Path Handling

n t oa ze Degree of Automation

Type and Level of Inventory and

Control of Materials



14/34



15/34


16/34

Product layout Layout that uses standardized processing

operations to achieve smooth, rapid, high-volumeflow

Layout that can handle varied processing

requirements

Fixed Position layout Layout in which the product or project remains

stationary, and workers, materials, and equipmentare moved as needed



17/34

Found in continuous production line flow ofrepetitive assembly or process

Suitable to produce high-volume quantity, highlystandardized products or repetitive processes.

In a product layout, resources are arranged

sequentially, based on the routing of the products.

E.g Production assembly for car, electronic device,circuit board



18/34

Standardized product

High production volume Stable production quantities

Uniform quality of raw materials &componen s



19/34



20/34



21/34

Lower variable cost perLower variable cost per

unitunit Lower material handlingLower material handling

costscosts


Lower workLower work--inin--processprocessinventories (WIP)inventories (WIP)

Easier training &Easier training &

supervisionsupervision Rapid throughputRapid throughput


22/34

Higher capitalHigher capitalinvestmentinvestment

S ecial e ui mentS ecial e ui ment


Any work stoppageAny work stoppagestops whole processstops whole process

Lack of flexibilityLack of flexibility

VolumeVolume

ProductProduct


23/34

A type of facility layout in which the floorplan is arranged with similar processes or

machines located together according to itsfunction.

For example, a machine shop with millslocated together, lathes located together,saws located together, and so on, is arrangedwith a process layout.

E.g Garment manufacturing, Car Workshop



24/34

Non-Standardized product, varies type

Medium rate production volume Variable production quantities



25/34

Flexibility. The firm has the ability to handle a variety ofprocessing requirements.

Motivation. Employees in this type of layout willprobably be able to perform a variety of tasks onmultiple machines, as opposed to the boredom of

. A process layout also allows the employer to use some

type of individual incentive system.

System protection. Since there are multiple machines

available, process layouts are not particularly vulnerableto equipment failures.



26/34



27/34

E.R.Triage

room

Patient B - erratic

acemaker

Patient A -

broken leg


E.R. beds Pharmacy Billing/exit

Hallway


28/34

Utilization. Equipment utilization rates in processlayout are frequently very low, because machine

usage is dependent upon a variety of outputrequirements.

Cost. , . Material handling is slower and more inefficient. The span of supervision is small due to job complexities

(routing, setups, etc.), so supervisory costs are higher. Other department like accounting, inventory control, and

purchasing usually are highly involved.

Confusion. Constantly changing schedules androutings make juggling process requirements moredifficult.



29/34

Fixed Position Layout: Layout in which theproduct or project remains stationary, andworkers, materials, and equipment are

.

Large construction projects e.g Aircraft &Ship manufacturing



30/34

In order to make this work, required resourcesmust be portable so that they can be taken to the

job for "on the spot" performance.



31/34



32/34



33/34


34/34


2.4 Facilities Layout Design_w3

Documents

Transcript of 2.4 Facilities Layout Design_w3