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FacilitiesChapter 5

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Objectives

Facility Layouts Process Layout Design Product Layout Design Hybrid Layouts Facility Location

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Facility Layouts

Layout characteristics Min handling cost, max utilization Safety, security, quality, flexibility

Basic layouts Process layout Product layout Fixed position 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 and

Shipping Assembly

Painting Department

Lathe Department

Milling Department Drilling Department

Grinding Department

P

P

4

1. Description Sequential arrangement Functional grouping

of machines of machines2. Type of Process Continuous, mass Intermittent,

job shopproduction, mainly batch

production,assembly mainly

fabrication3. Product Standardized Varied,

made to stock made to order4. Demand Stable Fluctuating5. Volume High Low6. Equipment Special purpose General purpose7. Workers Limited skills Varied skills

PRODUCT LAYOUTPRODUCT LAYOUT PROCESS LAYOUTPROCESS LAYOUT

8. Inventory Low in-process, High in-process,high finished goods low finished goods

9. Storage space Small Large10. Material Fixed path Variable path handling (conveyor) (forklift)11. Aisles Narrow Wide12. Scheduling Somewhat static Complex & dynamic13. Layout decision Line balancing Machine location14. Goal Equalize work at Minimize material each station handling cost15. Advantage Efficiency Flexibility

Compare

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Designing Process Layouts

Block Diagramming Minimize nonadjacent loads Use when quantitative data is

available Relationship Diagramming

Based on location preference between areas

Use when quantitative data is not available

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Block Diagramming

Create load summary chart

Calculate composite (2 way) movements

Develop trial layouts minimizing number of nonadjacent loads

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Load Summary Chart

Department A B C D E F

FROM/TO DEPARTMENT

A Radiology — 20 8 15B Lab — 30 10 2C Waiting — 25 15 23D Exam 25 15 25 — 7E Surgery 4 4 5 —F Therapy 10 3 20 5 —

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Relationship Diagramming

Used when quantitative data is not available

Muther’s grid table displays managers preferences for relative (pair wise) department locations

Denote location preferences with weighted lines in a diagram

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Muther’s Grid Table

E O

U U

O

OI

I

U

X O

U

AI

O

Radiology

Lab

Waiting

Exam

Surgery

Therapy

A Absolutely necessaryE Especially importantI ImportantO OkayUUnimportantXUndesirable

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Computerized Layout Solutions

CRAFT – block diagramming

CORELAP – relationship diagramming

Simulation

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Service Layouts

Tailored to customer needs Max flow and exposure Computer programs

consider Shelf space Demand Profitability

Aesthetically pleasing

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Designing Product Layouts

Arranged in assembly line Precedence diagram of tasks Jobs divided into work elements Work elements assigned to

workstations Workload balanced along the line

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Line Balancing Balance the amount of work at

each workstation Achieve a constant throughput

with high efficiency Line balancing process

Precedence diagram Desired cycle time Min number of workstations Group elements into

workstations with acceptable efficiency

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Precedence Table

Work Element Precedence Time (min)

A Tan leather — 30B Dye leather A 15C Shape case B 10D Mold hinges and fixtures —

5E Install hinges and fixtures C, D

10F Assemble case E

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Hybrid Layouts Cellular layouts

Group machines into machining cells

Flexible manufacturing systems Automated machining & material

handling systems Mixed-model assembly lines

Produce variety of models on one line

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Cellular Layouts Identify flow of

similar parts Group machines

into cells Arrange cells to min

material movement Locate shared

machines where cells connect

CA B Raw materials

Assembly

1

2

3

4

5

6 7

8

9

10

11

12

3

6

9

Assembly

12

4

8 10

5

7

11

12

A B CRaw materials

Cell 1 Cell 2 Cell 3

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Manufacturing Cell

InOut

Worker 1

Worker 2

Worker 3

Dir

ecti

on

of

par

t m

ove

men

t w

ith

in c

ell

Saw

Lathe

HorizontalMilling

VerticalMilling

Grinder

VerticalMilling

Lathe

Final inspection

Finished part

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FMS Layout Automated

machining, material handling, tool changers

Computer controlled system

Designed around part sizes and flow times

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Mixed Model Assembly Lines

Produce multiple models in any order on one assembly line

Issues in mixed model lines Line balancing U-shaped line Flexible workforce Model sequencing

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Facility Location Types of facilities

Heavy manufacturing Light industry Warehouses and distribution

centers Retail and service

Location factors Standard factors Global, regional, site factors Location incentives

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Location Analysis

Location factor rating

Center-of-gravity technique

Long-distance technique