Facility Layout and Work Design

Chapter 8Facility Layout and Work Design#Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternChapter 8 Facility and Work DesignFacility layout refers to the specific arrangementof physical facilities. Facility-layout studies arenecessary whenever (1) a new facility is constructed, (2) there is a significant change in demand or throughput volume, (3) a new good or service is introduced to the customer benefit package, or (4) different processes, equipment, and/or technology are installed. #2Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternChapter 8 Facility and Work DesignPurposes of layout studies are to: minimize delays in materials handling and customer movement, maintain flexibility, use labor and space effectively, promote high employee morale and customer satisfaction, provide for good housekeeping and maintenance, & enhance sales as appropriate in manufacturing and service facilities. ##3What is good layout for?Support the ability of operations to accomplish its missionflawed in some way, process efficiency and effectiveness suffers.For service firms, however, the facility layout is often duplicated in hundreds or thousands of sites. This makes it extremely important that the layout be designed properlyOperations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-Western#Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternChapter 8 Facility and Work DesignTypes of Facility LayoutsA product layout is an arrangement based on the sequence of operations that are performed during the manufacturing of a good or delivery of a service. Examples: winemaking industry, credit card processing, Subway sandwich shops, paper manufacturers, insurance policy processing, and automobile assembly lines. ##5Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternExhibit 8.1 Product Layout

##6Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternChapter 8 Facility and Work DesignTypes of Facility LayoutsA process layout consists of a functional grouping of equipment or activities that do similar work. Examples: legal offices, shoe manufacturing, jet engine turbine blades, and hospitals use a process layout.##7Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternExhibit 8.2 Process Layout for a Machine Shop

#8Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternChapter 8 Facility and Work DesignCellular/Group LayoutGroup technology, or cellular manufacturing, classifies parts into families so that efficient mass-production-type layouts can be designed for the families of goods or services. In a group, or cellular, layout, the design is not according to the functional characteristics of equipment, but rather by groups of different equipment (called cells) needed for producing families of goods or services. ##9Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternExhibit 8.3 Cellular Manufacturing Layout

Source: E. Paul Degarmo, J. T. Black, and Ronald A. Kosher, Materials and Processes in Manufacturing, 9th Edition, John Wiley & Sons, 2003.#10Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternChapter 8 Facility and Work DesignA fixed-position layout consolidates the resources necessary to manufacture a good or deliver a service, such as people, materials, and equipment, in one physical location. The production of large items such as heavy machine tools, airplanes, buildings, locomotives, and ships is usually accomplished in a fixed position layout.

##11Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternChapter 8 Facility and Work DesignMaterials Handling Issues and SystemsIndustrial trucks Fixed-path conveyor systems Overhead cranes Automated storage and retrieval systems (see OM Spotlight: Ocular Sciences Contact Lenses Distribution Center)Tractor-trailer systemsAutomated guided vehicles (AGVs)##12Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternChapter 8 Facility Layout in Service OrganizationsFacility Design in Service Organizations

Service organizations use product, process,group, and fixed-position layouts to organizedifferent types of work.

Process Layout ExamplesLibraries place reference materials, serials, andmicrofilms into separate areas; hospitals groupservices by function also, such as maternity,oncology, surgery, and X-ray; and insurancecompanies have office layouts in whichclaims, underwriting, and filing are individualdepartments.##13Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternExhibit 8.11Product Layout for a Pizza Kitchen

#14Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternExhibit 8.13Product Layout Design Options

#15Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternWorkplace design Questions

Who will use the workplaceHow will the work be performed? What tasks are required? How much time does each task take?What technology is needed?#Operations Management, 2e/Ch. 8 Facility and Work Design2007 Thomson South-WesternOTHER RELATED FACILITY AND WORKPLACE DESIGNErgonomics

Safety issues

Job design#