Lecture-6 8 Facilities Layout

8/8/2019 Lecture-6 8 Facilities Layout

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Facilities LayoutFacilities LayoutDr. KDS Pathania

Dr. KDS Pathania

LectureLecture -- 66


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Facility layoutFacility layout

MinimizematerialMinimizematerial--handlinghandlingcostscosts

Utilize spaceefficientlyUtilize spaceefficiently

UtilizelaborefficientlyUtilizelaborefficiently

EliminatebottlenecksEliminatebottlenecks FacilitatecommunicationFacilitatecommunication

andinteractionandinteraction

ReducemanufacturingcycleReducemanufacturingcycletimetime

ReducecustomerserviceReducecustomerservicetimetime

Eliminate wasted orEliminate wasted orredundantmovementredundantmovement

IncreasecapacityIncreasecapacity

Facilitate entry,exit,andFacilitate entry,exit,andplacement ofmaterial,placement ofmaterial,products,and peopleproducts,and people

Incorporate safetyandIncorporate safetyand

securitymeasuressecuritymeasures Promote productand servicePromote productand service

qualityquality

Encourage properEncourage propermaintenanceactivitiesmaintenanceactivities

Provideavisualcontrol ofProvideavisualcontrol ofactivitiesactivities

Provideflexibilityto adapttoProvideflexibilityto adapttochangingconditionschangingconditions

Arrangement ofareas withinafacilityto:


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Basic layoutsBasic layouts

Process layoutsProcess layouts

group similaractivities togetheraccordingtogroup similaractivities togetheraccordingtoprocess orfunctionthey performprocess orfunctionthey perform

ProductlayoutsProductlayouts arrangeactivities inlineaccordingto sequence ofarrangeactivities inlineaccordingto sequence of

operations fora particularproduct orserviceoperations fora particularproduct orservice

FixedFixed--positionlayoutspositionlayouts

areusedforprojects in which productcannotbeareusedforprojects in which productcannotbemovedmoved


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Process layout in servicesProcess layout in services

Womensessentials

Womensdresses

Womenssportswear

Shoes

Cosmeticsand jewelry

Entry anddisplay area

Housewares

Childrensdepartment

Mensdepartment


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Manufacturing Process LayoutManufacturing Process Layout

L

L

L

L

L

L

L

L

L

LM

M

M

M

D

D

D

D

D

D

D

D

G

G

G

G

G

G

A A AReceiving andShipping Assembly

Painting Department

Lathe DepartmentMilling

Department Drilling Department

GrindingDepartment

P

P


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AProduct LayoutAProduct Layout

InIn

OutOut


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Description

Type ofprocess

Product

Demand Volume Equipment

Description

Type ofprocess

Product

Demand Volume Equipment

Sequential

arrangement ofactivities

Continuous,mass

production,mainly

assembly

Standardized,madetostock

Stable

High

Special purpose

Process

Comparison ofProductComparison ofProduct

and Process Layoutsand Process Layouts

Functionalgrouping of

activities Intermittent, job shop,

batch production,

mainlyfabrication

Varied,madeto order

Fluctuating

Low General purpose

Product


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Workers

Inventory

Storage space

Materialhandling

Aisles

Scheduling

Layoutdecision

Goal

Advantage

Workers

Inventory

Storage space

Materialhandling

Aisles

Scheduling

Layoutdecision

Goal

Advantage

Limited skills

Low in-process,high

finishedgoods Small

Fixed path (conveyor)

Narrow

Part ofbalancing

Linebalancing

Equalize workateach

station

Efficiency

Process

Comparison ofProductComparison ofProduct

and Process Layoutsand Process Layouts

Varied skills

Highin-process,low

finishedgoods Large

Variable path (forklift)

Wide

Dynamic

Machinelocation

Minimizematerial

handlingcost

Flexibility

Product


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FixedFixed--Position LayoutsPosition Layouts

Typical ofprojectsTypical ofprojects

Equipment, workers,Equipment, workers,

materials, othermaterials, other

resources broughttoresources broughttothe sitethe site

Highly skilledlaborHighly skilledlabor

Oftenlow fixedOftenlow fixed

TypicallyhighvariableTypicallyhighvariable

costscosts


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Designing Process LayoutsDesigning Process Layouts

Goal: minimizematerialhandlingcostsGoal: minimizematerialhandlingcosts

BlockDiagrammingBlockDiagramming

minimizenonadjacentloadsminimizenonadjacentloads

use when quantitativedatais availableuse when quantitativedatais available

Relationship DiagrammingRelationship Diagramming

based onlocation preferencebetweenareasbased onlocation preferencebetweenareas

use when quantitativedatais notavailableuse when quantitativedatais notavailable


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Block DiagrammingBlock Diagramming

UnitloadUnitload

quantityin whichquantityin which

materialis normallymaterialis normally

movedmoved

NonadjacentloadNonadjacentload

distancefartherthanthedistancefartherthanthe

nextblocknextblock

StepsSteps

createload summarycreateload summary

chartchart

calculatecomposite (twocalculatecomposite (twoway)movementsway)movements

develop triallayoutsdevelop triallayouts

minimizingnumberofminimizingnumberof

nonadjacentloadsnonadjacentloads


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Block Diagramming: ExampleBlock Diagramming: Example

DepartmentDepartment 11 22 33 44 55

Load Summary ChartLoad Summary Chart

FROM/TOFROM/TO DEPARTMENTDEPARTMENT

11 100100 5050

22 200200 5050

33 6060 4040 5050

44 100100 606055 5050

1 2 3

4 5


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Block Diagramming:Block Diagramming:Example (cont.)Example (cont.)

2 3 200loads

2 4 150loads

1 3 110loads1 2 100loads

4 5 60loads

3 5 50loads

25 5

0loads3 4 40loads

1 4 0loads

1 5 0loads

1 2 3

4 5

100 200

150

50

50

60

40

110

Grid 1

NonadjacentLoads:

110+40=150

1 2

3

4

5

100

200

150

50

50

60

40

110

Grid 2

NonadjacentLoads:

0


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Block Diagramming:Block Diagramming:Example (cont.)Example (cont.)

12

3

4

53

2

5

1 4

(a) Initial block diagram(a) Initial block diagram (b) Final block diagram(b) Final block diagram


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Relationship DiagrammingRelationship Diagramming

SchematicdiagramthatSchematicdiagramthat

uses weightedlines touses weightedlines to

denotelocationdenotelocation

preferencepreference Muthers gridMuthers grid

formatfordisplayingformatfordisplaying

managerpreferences formanagerpreferences for

departmentlocationsdepartmentlocations


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RelationshipRelationship

DiagrammingDiagramming

ProductionProduction

OfficesOffices

StockroomStockroom

Shipping andShipping andreceivingreceiving

Locker roomLocker room

ToolroomToolroom

AA AA

AA

OO

OO

OOOO OO

UU

UU

UU

UU

EEXX

II

A Absolutelynecessary

E Especiallyimportant

I ImportantO Okay

U Unimportant

X Undesirable


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Relationship Diagrams:Relationship Diagrams:Example (cont.)Example (cont.)

(a) Relationship diagram of original layout(a) Relationship diagram of original layout

Key:Key: AAEE

II

OO

UU

XX

OfficesOffices

StockroomStockroom

LockerLockerroomroom

ToolroomToolroom

ShippingShippingandand

receivingreceiving

ProductionProduction


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(b) Relationship diagram of revised layout(b) Relationship diagram of revised layout

OfficesOffices

StockroomStockroom

LockerLockerroomroom

ToolroomToolroom

ShippingShippingandand

receivingreceiving

ProductionProduction Key:Key: AAEE

II

OO

UU

XX

Relationship Diagrams:Relationship Diagrams:Example (cont.)Example (cont.)


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Computerized layout solutionsComputerized layout solutions

CRAFTCRAFT ComputerizedRelative Allocation ofFacilities TechniqueComputerizedRelative Allocation ofFacilities Technique

CORELAPCORELAP

ComputerizedRelationship Layout PlanningComputerizedRelationship Layout Planning PROMODELandEXTENDPROMODELandEXTEND

visualfeedbackvisualfeedback

allow userto quicklytestavariety ofscenariosallow userto quicklytestavariety ofscenarios

ThreeThree--Dmodelingand CADDmodelingand CAD integratedlayoutanalysisintegratedlayoutanalysis

availableinVisFactoryand similarsoftwareavailableinVisFactoryand similarsoftware


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Designing Service LayoutsDesigning Service Layouts

MustbebothattractiveandfunctionalMustbebothattractiveandfunctional

TypesTypes

Freeflow layoutsFreeflow layouts

encouragebrowsing,increaseimpulse purchasing,areflexibleandencouragebrowsing,increaseimpulse purchasing,areflexibleandvisuallyappealingvisuallyappealing

GridlayoutsGridlayouts

encouragecustomerfamiliarity,arelow cost,easyto cleanandencouragecustomerfamiliarity,arelow cost,easyto cleanand

secure,andgoodforrepeatcustomerssecure,andgoodforrepeatcustomers

Loop andSpinelayoutsLoop andSpinelayouts

bothincreasecustomersightlines andexposureto products, whilebothincreasecustomersightlines andexposureto products, while

encouraging customerto circulatethroughtheentire storeencouraging customerto circulatethroughtheentire store


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Types of Store LayoutsTypes of Store Layouts


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Designing Product LayoutsDesigning Product Layouts

ObjectiveObjective BalancetheassemblylineBalancetheassemblyline

LinebalancingLinebalancing

tries to equalizetheamount ofworkateach workstationtries to equalizetheamount ofworkateach workstation PrecedencerequirementsPrecedencerequirements

physicalrestrictions onthe orderin which operations arephysicalrestrictions onthe orderin which operations areperformedperformed

CycletimeCycletime maximumamount oftimea productis allowedto spendatmaximumamount oftimea productis allowedto spendat

each workstationeach workstation


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Cycle Time ExampleCycle Time Example

Cd =production time available

desired units of output

Cd=

(8 hours x 60 minutes / hour)

(120 units)

Cd

= =4 minutes480

120


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Flow Time vs Cycle TimeFlow Time vs Cycle Time

Cycletime=maxtime spentatany stationCycletime=maxtime spentatany station

Flow time=timeto completeall stationsFlow time=timeto completeall stations

1 2 3

4 minutes4 minutes 4 minutes4 minutes 4 minutes4 minutes

Flow time = 4 + 4 + 4 = 12 minutesFlow time = 4 + 4 + 4 = 12 minutes

Cycle time = max (4, 4, 4) = 4 minutesCycle time = max (4, 4, 4) = 4 minutes


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Efficiency of Line

ii

ii= 1= 1ttii

nCnCaaEE==

ii

ii= 1= 1ttii

CCddNN==

EfficiencyEfficiencyMinimum numberMinimum number

of workstationsof workstations

wherewhere

ttii = completion time for element= completion time for element ii

jj = number of work elements= number of work elements

nn = actual number of workstations= actual number of workstations

CCaa

= actual cycle time= actual cycle time

CCdd

= desired cycle time= desired cycle time


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Line Balancing ProcedureLine Balancing Procedure

1. Draw andlabela precedencediagram

2. Calculate desiredcycletimerequiredfortheline

3. Calculate theoreticalminimumnumberofworkstations

4. Group elements into workstations,recognizingcycletimeand precedenceconstraints

5. Calculate efficiency oftheline

6. Determineifthetheoreticalminimumnumberof

workstations oranacceptableefficiencylevelhasbeenreached. Ifnot,go backto step 4.


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Line Balancing: ExampleLine Balancing: Example

WORK ELEMENTWORK ELEMENT PRECEDENCEPRECEDENCE TIME (MIN)TIME (MIN)

AA Press out sheet of fruitPress out sheet of fruit 0.10.1

BB Cut into stripsCut into strips AA 0.20.2

CC Outline fun shapesOutline fun shapes AA 0.40.4DD Roll up and packageRoll up and package B, CB, C 0.30.3

0.10.1

0.20.2

0.40.4

0.30.3D

B

C

A


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Line Balancing: Example (cont.)Line Balancing: Example (cont.)

WORK ELEMENTWORK ELEMENT PRECEDENCEPRECEDENCE TIME (MIN)TIME (MIN)

AA Press out sheet of fruitPress out sheet of fruit 0.10.1

BB Cut into stripsCut into strips AA 0.20.2

CC Outline fun shapesOutline fun shapes AA 0.40.4DD Roll up and packageRoll up and package B, CB, C 0.30.3

Cd

=

=

=0.4 minute

40 hours x 60 minutes / hour

6,000 units

2400

6000

N= = = 2.5 3 workstations1.0

0.4

0.1 + 0.2 + 0.3 + 0.4

0.4


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CCdd

= 0.4= 0.4

NN= 2.5= 2.5

REMAINING REMAININGWORKSTATION ELEMENT TIME ELEMENTS

1 A 0.3 B, C

B 0.1 C, D

2 C 0.0 D3 D 0.1 none

0.10.1

0.20.2

0.40.4

0.30.3D

B

C

A


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A, B C D

Work

station 1

Work

station 2

Work

station 3

0.3

minute

0.4

minute

0.3

minute

CCdd

= 0.4= 0.4

NN= 2.5= 2.5

E= = = 0.833 = 83.3%0.1 + 0.2 + 0.3 + 0.4

3(0.4)

1.0

1.2



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Computerized Line BalancingComputerized Line Balancing

Useheuristics to assigntasks to workstationsUseheuristics to assigntasks to workstations

Longest operationtimeLongest operationtime

Shortest operationtimeShortest operationtime

MostnumberoffollowingtasksMostnumberoffollowingtasks

LeastnumberoffollowingtasksLeastnumberoffollowingtasks

Ranked positional weightRanked positional weight


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CellularLayouts

1.1. Identifyfamilies ofparts with similarIdentifyfamilies ofparts with similar

flow pathsflow paths

2.2. Group machines into cells based onGroup machines into cells based on

partfamiliespartfamilies

3.3. Arrangecells so materialmovementArrangecells so materialmovement

is minimizedis minimized

4.4. Locatelarge sharedmachines atLocatelarge sharedmachines atpoint ofusepoint ofuse


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Parts FamiliesParts Families

A family ofA family of

similar partssimilar parts

A family of relatedA family of related

grocery itemsgrocery items


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Original Process LayoutOriginal Process Layout

CA B Raw materials

Assembly

1

2

3

4

5

6 7

8

9

10

11

12


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Part Routing MatrixPart Routing Matrix

Machines

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

A x x x x x

B x x x x

C x x x

D x x x x x

E x x x

F x x xG x x x x

H x x x

Figure 5.8Figure 5.8


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Revised CellularLayoutRevised CellularLayout

3

6

9

Assembly

12

4

8 10

5

7

11

12

A B C

Raw materials

Cell 1 Cell 2 Cell 3


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Reordered Routing MatrixReordered Routing Matrix

Machines

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

A x x x x x

D x x x x x

F x x x

C x x x

G x x x x

B x x x xH x x x

E x x x


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Key:Key:

SS = Saw= Saw

LL =Lathe=Lathe

HMHM = Horizontal milling machine= Horizontal milling machine

VMVM = Vertical milling machine= Vertical milling machine

GG = Grinder= Grinder

Paths of threePaths of threeworkers movingworkers moving

within cellwithin cell

MaterialMaterial

movementmovement

InIn OutOut

Worker 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

Finalinspection

Finishedpart

A Manufacturing Cell with

WorkerPathsSource: J.T. Black, Cellular Manufacturing

Systems Reduce Setup Time, Make Small Lot

Production Economical.IndustrialEngineering(November1983).


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Automated Manufacturing CellAutomated Manufacturing Cell

Source: J. T. Black, Cellular

Manufacturing Systems Reduce Setup

Time, Make Small Lot

Production Economical. Industrial

Engineering(November1983)


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Advantages and DisadvantagesAdvantages and DisadvantagesofCellularLayoutsofCellularLayouts AdvantagesAdvantages

ReducedmaterialReducedmaterial

handlingandtransittimehandlingandtransittime

Reduced setup timeReduced setup time

Reduced workReduced work--inin--

process inventoryprocess inventory

Betteruse ofhumanBetteruse ofhuman

resourcesresources

Easierto controlEasierto control

Easierto automateEasierto automate

DisadvantagesDisadvantages

Inadequate partfamiliesInadequate partfamilies

PoorlybalancedcellsPoorlybalancedcells

ExpandedtrainingandExpandedtrainingandschedulingscheduling

ofworkersofworkers

IncreasedcapitalIncreasedcapital

investmentinvestment


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Flexible Manufacturing SystemsFlexible Manufacturing Systems(FMS)(FMS) FMSconsists ofnumerous programmableFMSconsists ofnumerous programmable

machinetools connectedbyanautomatedmachinetools connectedbyanautomatedmaterialhandling systemandcontrolledbyamaterialhandling systemandcontrolledbya

commoncomputernetworkcommoncomputernetwork FMScombines flexibility withefficiencyFMScombines flexibility withefficiency

FMSlayouts differbased onFMSlayouts differbased on

variety ofparts thatthe systemcan processvariety ofparts thatthe systemcan process

size of parts processedsize of parts processed

average processingtimerequiredforpartaverage processingtimerequiredforpartcompletioncompletion


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Full-Blown FMS


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Mixed Model Assembly LinesMixed Model Assembly Lines

Producemultiplemodels inany orderon oneProducemultiplemodels inany orderon one

assemblylineassemblyline

Issues inmixedmodellinesIssues inmixedmodellines

LinebalancingLinebalancing

UU--shapedlineshapedline

Flexible workforceFlexible workforce

Model sequencingModel sequencing


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Balancing UBalancing U--Shaped LinesShaped Lines

A B C

D E

Precedence diagram:Precedence diagram:

Cycle time = 12 minCycle time = 12 min

A,B C,D E

(a) Balanced for a straight line(a) Balanced for a straight line

9 min9 min 12 min12 min 3 min3 min

Efficiency = = = .6666 = 66.7 %Efficiency = = = .6666 = 66.7 %24243636

24243(12)3(12)

12 min12 min 12 min12 min

C,D

A,B

E

(b) Balanced for a U(b) Balanced for a U--shaped lineshaped line

Efficiency = = = 100 %Efficiency = = = 100 %2424

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2(12)2(12)

Lecture-6 8 Facilities Layout

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