3 facility layout
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Facil i ty LayoutFacil i ty Layout
Dr. Everette S. Gardner, Jr.
Facility Layout 2
Machine shop process layout Receiving Grin-
Mills ders
Raw matl. Large number of
storage Assem- low volume bly products
Drills Planers
Finished Inspec- goods
Lathes Automatics tion storage
Part A Part B
Facility Layout 3
Product layout
Raw matl. Fabrication Rec- storage line-part B eiving Fabrication Planer
line-part A Finished Lathe
goods Drill storage Mill
Mill Drill
Grinder Mill
Assembly line Automatic
Small numberof
high volumeproducts
Facility Layout 4
Possible solutions to the process layout problem6 Department problem has 6! or 720 possible solutions:
A B C
D E F
I.E., there are 720 different arrangements of the 6 departments on the 6 locations on the grid.
Facility Layout 5
Possible solutions to the process layout problem (cont.)
Problem complexity grows exponentially:
Nbr. depts. Solutions 10 3,628,800
15 1.31 x 10^12 20 2.43 x 10^18 50 3.04 x 10^64
Facility Layout 6
Solutions considered by Craft
• N! solut ions to problem with N depts.
• Craft considers only
N(N-1) pairs of exchanges, 2 starting with each
dept.
Facility Layout 7
Craft init ial layout of furniture plant
A B C
D E
F G
I H
J
TOTAL COST = $2524.68
Facility Layout 8
Craft f inal layout
A E C I G F B H J D
TOTAL COST = $766.68
Facility Layout 9
Synopsis of assembly l ine balancing
1. Set up a precedence table.
2. Compute required cycle t ime:C = (production time) / (required output in units)
3. Compute minimum cycle t ime:CMIN = time for longest task
4. Compute minimum number of stat ions:SMIN = (sum of all times) / C
Facility Layout 10
Synopsis of assembly l ine balancing (cont.)5. Select rule by which tasks are assigned to work
stations.Examples:
(1) select tasks with longest operation times first or(2) select tasks with largest number of following tasks first
6. Assign tasks to the first work station unti l the sum of the task times are equal to the cycle t ime, or no other tasks are feasible. Repeat for stations 2, 3, … unti l tasks are assigned.
7. Evaluate the efficiency of the balance:E = (sum of all times) / (actual nbr. of stations x C)
Facility Layout 11
Line balancing quiz
0.4 0.3 1.1 1.1 0.5 0.7 0.3 1.2 0.4 0.8
Balance this production line to achieve an output of 367 units per day. Available production time is 8 hrs. less a 40 min. lunch break. Use the largest number of following tasks rule to select tasks for work stations. Break ties with the longest operation time.
A
B
C
D
E
F
G
H
I J
Facility Layout 12
Multiple solutions in l ine balancing
6 4
7 3 5 5 5
2
A
B
C
D
E
F
G
H
Facility Layout 13
Multiple solutions in l ine balancing (cont.)
84
25
3
1 2 3 4 5 6 7 Stations
Num
ber o
f sol
utio
ns
Facility Layout 14
Volvo layouts
Rotatinground tablewith definitecycle time --facilitates teamwork
Facility Layout 15
Volvo layouts (cont.)
Horseshoeconveyorsections to enable workercommunications
Facility Layout 16
Volvo layouts (cont.)
Interim storage Storage areas to separate
line into definitesupervisory groups
Supervisor Supervisor B A
Facility Layout 17
Volvo layouts (cont.)
Machines groupedin banks of 3so workers canexchange jobs andassist each otherin set-up
Facility Layout 18
Volvo continued
Connections of subassembly islands feed parts/components to end-assembly islands—each island functions as a separate team
E
S
S
S
E
E
S
S
S