Facilities Planning - Unit 04 Layout Types: Manufacturing.

Facilities Planning Facilities Planning - Unit 04- Unit 04

Layout Types: ManufacturingLayout Types: Manufacturing

Layout Types: Manufacturing - 2

Hierarchy of Facility PlanningHierarchy of Facility PlanningLayout DesignLayout Design

Facility Planning

Structural Design

Facility Location

Facility Design

Handling System Design

Layout Design

Source for Figure: Tompkins and White, Facilities Planning, 2nd edition, Wiley


Layout DesignLayout Design

Facility layoutFacility layout means planning: for the location of all machines, utilities, employee

workstations, customer service areas, material storage areas, aisles, restrooms, lunchrooms, internal walls, offices, and computer rooms

for the flow patterns of materials and people around, into, and within buildings


Layout DesignLayout DesignPlanning for required Spaces and AreasPlanning for required Spaces and Areas

Equipment Work stations Material storage Rest/break areas Utilities Eating areas Aisles Offices


Location of these various areas impacts the flow through the system.

The layout can affect productivity and costs generated by the system.

Layout alternatives are limited by the amount and type of space required for the

various areas the amount and type of space available the operations strategy

Layout Design – Layout Design – IntroductionIntroduction Characteristics of the Facility Layout Decision Characteristics of the Facility Layout Decision


Basic Layout TypesBasic Layout Types

Product Layouts Process Layouts Fixed-position layouts Cellular/Group technology layouts


Basic Layout TypesBasic Layout TypesProduct Volume vs. Product VarietyProduct Volume vs. Product Variety

Low Medium High

High

Medium

Low

Product Planning

Department

Fixed Materials Location Planning

Department

Process Planning

Department

Product Family Planning

Department

Product Layout

Fixed Location Layout

Group Technology Layout

Process LayoutVolu

me

Variety


Types of LayoutTypes of LayoutFixed Position LayoutFixed Position Layout

Lathe Press Grind

Weld AssemblyPaint

Storage

Warehouse


Types of LayoutTypes of LayoutFixed Position LayoutFixed Position Layout

Layout in which the product or project remains stationary, and

workers, materials, and equipment are moved as needed.

Examples:Examples:

Large construction projects (buildings, power plants, dams)

Shipbuilding, production of large aircraft

Rockets used to launch space missions


Types of LayoutTypes of LayoutFixed Position Layout: AdvantagesFixed Position Layout: Advantages

Material movement is reduced. Promotes job enlargement by allowing

individuals or teams to perform the “whole job”.

Continuity of operations and responsibility results from team.

Highly flexible; can accommodate changes in product design, product mix, and product volume.

Independence of production centers allowing scheduling to achieve minimum total production time.


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.

Types of LayoutTypes of LayoutFixed Position Layout: LimitationsFixed Position Layout: Limitations


Drill Grind Drill

Lathe

Drill

Drill

Storage

Warehouse

Assembly

Lathe

Bend

Lathe

Mill

Press

Drill

Types of LayoutTypes of LayoutProduct Type LayoutProduct Type Layout


Types of LayoutTypes of LayoutProduct Type Layout - RequirementsProduct Type Layout - Requirements

Standardized product High production volume Stable production quantities Uniform quality of raw materials & components


Types of LayoutTypes of LayoutProduct Type Layout - AssumptionsProduct Type Layout - Assumptions

Volume is adequate for high equipment utilization Product demand is stable enough to justify high

investment in specialized equipment Product is standardized or approaching a phase of its

life cycle that justifies investment in specialized equipment

Supplies of raw materials and components are adequate and of uniform quality ensure they will work with specialized equipment


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 so 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 control systems are possible.

Less space is occupied by work in transit and for temporary storage.

Types of LayoutTypes of LayoutProduct Type Layout - AdvantagesProduct Type Layout - Advantages


A breakdown of one machine may lead to a 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 alternations in the layout.

The “pace” of production is determined by the slowest machine.

Supervision is general, rather than specialized. Comparatively high investment is required, as

identical machines (a few not fully utilized) are sometimes distributed along the line.

Types of LayoutTypes of LayoutProduct Type Layout - LimitationsProduct Type Layout - Limitations


Lathe Drill Weld

Mill

Drill

Grind

Storage

Warehouse

Lathe

Lathe

Mill

Mill

Lathe

Mill

Paint

Grind

Assembly

Assembly

Paint

Weld

Types of LayoutTypes of LayoutProcess Type LayoutProcess Type Layout


Process type layouts can handle varied processing requirements

The layouts feature departments or other functional groupings in which similar kinds of activities are performed

Examples:Examples: Machine shops usually have separate departments for milling, grinding, drilling, and so on

Different products may present quite different processing requirements and sequences of operations



Process Layout - work travels to dedicated process centers

Milling

Assembly Test Grinding

Drilling Plating



A high degree of flexibility exists relative to equipment or manpower allocation for specific tasks.

Comparatively low investment in machines is required.

The diversity of tasks offers a more interesting and satisfying occupation for the operator.

Types of LayoutTypes of LayoutProcess Type Layout - AdvantagesProcess Type Layout - Advantages


Since longer flow lines usually exist, 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 result. 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 LayoutTypes of LayoutProcess Type Layout - LimitationsProcess Type Layout - Limitations


Types of LayoutTypes of LayoutProcess Layout vs. Product LayoutProcess Layout vs. Product Layout


Drill Grind Assembly

Drill

Weld

Assembly

Storage

Warehouse

Lathe

Assembly

Grind

Press

Mill

Lathe

Paint

Drill

Drill

Press

Grind

Assembly

Types of LayoutTypes of LayoutGroup Technology/Cellular/Product Family LayoutGroup Technology/Cellular/Product Family Layout


Group Technology (GT) is a management philosophy that attempts to group products with similar design or manufacturing characteristics, or both.

Cellular Manufacturing (CM) is an application of GT that involves grouping machines based on the parts manufactured by them.

The main objective of CM is to identify machine cells and part families simultaneously, and to allocate part families to machine cells in a way that minimizes the intercellular movement of parts.

Types of LayoutTypes of LayoutGroup Technology vs. Cellular ManufacturingGroup Technology vs. Cellular Manufacturing


Original Process LayoutOriginal Process Layout

CA B Raw materials

Assembly

1

2

3

4

5

6 7

8

9

10

11

12

Types of LayoutTypes of LayoutGroup Technology/Cellular Layout – Example A (page 1)Group Technology/Cellular Layout – Example A (page 1)


Original Part Routing MatrixOriginal Part Routing Matrix


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

A x x x x xB x x x xC x x xD x x x x xE x x xF x x xG x x x xH x x x


Reordered Part Routing MatrixReordered Part Routing Matrix


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

A x x x x xD x x x x xF x x xC x x xG x x x xB x x x xH x x xE x x x


Revised Cellular LayoutRevised Cellular Layout


3

6

9

Assembly

12

4

8 10

5

7

11

12

A B CRaw materials

Cell 1 Cell 2 Cell 3


Types of LayoutTypes of LayoutGroup Technology/Cellular Layout – Example B (page 1)Group Technology/Cellular Layout – Example B (page 1)

Unorganized Parts


Process Flows before the Use of GT Cells



Transition from Process Layout


1. Grouping parts into families that follow a common sequence of steps.

2. Identifying dominant flow patterns of parts families as a basis for location or relocation of processes.

3. Physically grouping machines and processes into cells.


Grouping parts into families



Process flows after the Use of GT Cells



AAAA AAAA

BBBBBBBBB BBBB

Ass

embl

y

CCCCCCCCCC CCCC

DDDDDDDDDDDDDD DDDD

Lathe

Lathe

Mill

Mill

Mill

Mill

Drill

Drill

Drill

Heat treat

Heat treat

Heat treat

Gear cut

Gear cut

Grind

Grind

Types of LayoutTypes of LayoutGroup Technology/Cellular LayoutGroup Technology/Cellular Layout

Related topic: Mixed model Assembly/manufacturing


Types of LayoutTypes of LayoutGroup Technology/Cellular LayoutGroup Technology/Cellular Layout

A family of similar partsA family of similar parts A family of related grocery itemsA family of related grocery items

Grouping parts into families


Types of LayoutTypes of LayoutGroup Technology vs. Cellular ManufacturingGroup Technology vs. Cellular Manufacturing

Potential benefits of CMPotential benefits of CM Setup time reduction Work-in-process (WIP)

reduction Material handling cost reduction Direct/indirect labor cost

reduction

Improvement in quality Improvement in material flow Improvement in machine

utilization Improvement in space

utilization Improvement in employee moral


Basic Layout TypesBasic Layout TypesProduct Volume vs. Product VarietyProduct Volume vs. Product Variety

Low Medium High

High

Medium

Low

Product Planning

Department

Fixed Materials Location Planning

Department

Process Planning

Department

Product Family Planning

Department

Product Layout

Fixed Location Layout

Group Technology Layout

Process LayoutVolu

me

Variety


Dimension Functional Cellular

Number of moves between departments Many Few

Travel distances Longer Shorter

Travel paths Variable Fixed

Job waiting times Greater Shorter

Throughput time Higher Lower

Amount of work in process Higher Lower

Supervision difficulty Higher Lower

Scheduling complexity Higher Lower

Equipment utilization Lower Higher

Types of LayoutTypes of LayoutProcess (Functional) Layout vs. Cellular LayoutProcess (Functional) Layout vs. Cellular Layout

Layout Types: Manufacturing - 39 Layout Types: Manufacturing - 39

Key:Key:SS = Saw= SawLL = Lathe= LatheHMHM = Horizontal milling = Horizontal milling

machinemachineVMVM = Vertical milling = Vertical milling

machinemachineGG = Grinder= Grinder

Paths of three Paths of three workers moving workers moving within cellwithin cell

Material Material movementmovement

InIn OutOutWorker 1Worker 1

Worker 2Worker 2

Worker 3Worker 3

Direction of part movement within cellDirection of part movement within cell

S

L

HM

VM

G

VM

L

Final inspection

Finished part

A Manufacturing Cellwith Worker Paths

Types of Layout - Types of Layout - ExampleExample


Types of Layout Types of Layout - Example- ExampleManufacturing CellManufacturing Cell

Animated Picture


Types of Layout Types of Layout - Example- ExampleManufacturing CellManufacturing Cell

An example of a hybrid layoutAn example of a hybrid layout


Types of Layout Types of Layout - Example- ExampleAutomated Manufacturing CellAutomated Manufacturing Cell



Types of Layout Types of Layout - Example- ExampleFlexible Manufacturing CellFlexible Manufacturing Cell



Work CellWork Cell Assembly or Production line-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility. Cells can be formed on a temporary basis.

Example: job shop with rearranged machinery and personnel to produce 30 unique control panels

Focused WorkFocused WorkCenterCenter

A permanent assembly-line-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility

Example: manufacturing of pipe brackets at a shipyard

Focused FactoryFocused Factory A permanent facility to produce a product or component in a product-oriented facility

Example: a plant to produce window mechanisms for automobiles

Types of LayoutTypes of LayoutWork Cell, Focused Work Center, and Focused FactoryWork Cell, Focused Work Center, and Focused Factory


Straight-line Flow Pattern when possible Backtracking kept to a Minimum Predictable Production Time Little In-process materials storage Open Floor plans so everyone can see what is going on Bottlenecks under control Workstations close together Minimum of material handling Easy adjustment to changing conditions

Principles of a Good LayoutPrinciples of a Good LayoutManufacturingManufacturing


New Trends in Manufacturing LayoutsNew Trends in Manufacturing Layouts

Designed for quality and flexibility Ability to quickly shift to different product models or to

different production rates Cellular layout within larger process layouts Automated material handling U-shaped production lines use to better accomplish flow control

More open work areas with fewer walls, partitions, or other obstacles

Smaller and more compact factory layouts Less space provided for storage of inventories

throughout the layout


Wrap-UpWrap-UpWorld-Class PracticesWorld-Class Practices

Strive for flexibility in layouts Multi-job training of workers Sophisticated preventive-maintenance programs Flexible machines Empowered workers trained in problem solving Layouts small and compact

Services follow the above practices plus incorporate customer needs in design


Wrap-upWrap-upAttaining Lean ProductionAttaining Lean Production

Focus on inventory reduction Build systems that help employees Reduce space requirements Develop close relationships with suppliers Educate suppliers Eliminate all but value-added activities Develop the workforce Make jobs more challenging Set sights on perfection!

Facilities Planning - Unit 04 Layout Types: Manufacturing.

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Transcript of Facilities Planning - Unit 04 Layout Types: Manufacturing.