Facilities Layout (September 2014)

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Facilities Layout

Industrial Management 1

Industrial Management 1

Prepared by:Industrial Systems Engineering Research Group

Universiti Tun Hussein Onn Malaysia


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Learning Objectives

List some reasons for layoutsdesign

Describe the basic layout types List the advantages and

disadvantages of layout designs.

Develop simple process layouts(using computer software)


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Layout: the conguration of departments,work centers, and euipment, withparticular emphasis on movement of work(customers or materials) through thesystem.

!roduct layouts

!rocess layouts

"i#ed$!osition layout

%ombination layouts

Facilities Layout


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Objective of Layout

Design&. "acilitate attainment of product or service

uality

'. se workers and space eciently

*. +void bottlenecks

. -inimie unnecessary material handlingcosts

/. 0liminate unnecessary movement ofworkers or materials

1. -inimie production time or customerservice time

2. Design for safety


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Inefficient operations

For Example:

High CostBottlenecks

Changes in the design

of products or services

The introduction of newproducts or services

Accidents

afet! ha"ards

The Need for Layout

Design


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Changes in

environmental

or other legalre#uirements

Changes in volume of

output or mix of

products

Changes in methodsand e#uipment

$orale pro%lems

The Need for LayoutDesign (Contd)


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!roduct layout tilies standardied processing

operations to achieve smooth, rapid,high$volume 3ow

!rocess layout+ble to handle variety process

reuirements

"i#ed !osition layout!roduct (or pro4ect) remains stationary,

whereas workers$materials$euipment

Basic Layout


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Raw materials

or customer

Finished

itemStation

2

Station

2

Station

3

Station

3

Station

4

Station

4

Material

and/or

labor

Station

1

Material

and/or

labor

Material

and/or

labor

Material

and/or

labor

Used for Repetitive or Continuous Processing

Product Layout(seuential)Utilizesstandardized process operations to achieve smooth, rapid,

high-volume flow


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5igh volume production (high prod6nrate)

Low cost per unit product Low cost in material handling

5igh utiliation of labour$euipment Labour specialiation (specic works)

0stablished routing and scheduling

+dvantages of !roduct

Layout


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7epetitive 4obs

Low skill workers may not maintain uality

of output (impair uality) 8ot 3e#ible to change in volume.

9mpair output rate when breakdown(shutdown)

!reventive maintenance is critical.

Disadvantages of !roductLayout


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Dept. A

(Stamping)

Dept. B

(Lathe)

Dept. D

(Grinding)

Dept. C

(Milling)

Dept. F

(Coating)

Dept. E

(Etching)

Used for Intermittent processing

Job Sop or B!tc Processes

Process Layout (functional)

rocess Layout


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Process Layout+ble to handle variety of process reuirements

Used for Intermittent processing

Job Sop or B!tc Processes


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+ble to handle variety of processreuirements.

8ot aected production rate when machinefailures.

Low cost in euipment utiliation.

!ossible to create individual (worker)incentive plans

+dvantages of !rocessLayouts


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9n$process inventory costs can be high

%hallenging routing and scheduling

0uipment utiliation rates are low -aterial handling slow and inecient

%omple#ities often reduce span of

supervision ;pecial attention for each product or

customer

+ccounting and purchasing are more

involved

Disadvantages of !rocessLayouts


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Large construction project (in real world)

Fixed Position Laout

(!imulation)

Fixed Position Layout

"ature of product#& $eight& !ize& %ul&


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'


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1 2 3 4

5

6

7891

In

Out

Workers

$;haped !roduction Line


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%ellular !roduction Layout in which machines are

grouped into a cell that canprocess items that have similarprocessing reuirements

=roup >echnology>he grouping into part families

of items with similar design ormanufacturing characteristics

Cellular Layouts


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'hroughput time higher lo&er

+mount of work inprocess

higher lo&er

;upervisiondiculty

higher lo&er

;cheduling

comple#ity

higher lo&er

Table 6!

"unctional vs. %ellularLayouts

Facilities Layout (September 2014)

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