facility layout session 2
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8/6/2019 Facility Layout Session 2
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Facility Location
Process Designand
Facility Layout
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Introduction
• Process selection
– Deciding on the way production of
goods or services will be organized
• Major implications – Capacity planning
– Layout of facilities
– Equipment, Capital-equipment or
labor intensive – Design of work systems
• New product and service,
technological changes, and
competitive pressures
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Process Types
• Job Shops: Small lots, low volume, general equipment,skilled workers, high-variety. Ex: tool and die shop,
veterinarian’s office
• Batch Processing: Moderate volume and variety. Variety
among batches but not inside. Ex : paint production ,
• Repetitive/Assembly: Semi continuous , high volume of
standardized items, limited variety. Ex: auto plants,
cafeteria
• Continuous Processing: Very high volume , no variety.
Ex: steel mill, chemical plants
• Projects: Non routine jobs. Ex: preparing metro rail
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Dimension Job Shop Batch Repetitive Continuous
Job variety Very High Moderate Low Very low
Processflexibility
Very High Moderate Low Very low
Unit cost Very High Moderate Low Very low
Volume of output
Very low Low High Very high
Product – Process Matrix
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Process Type High variety Low variety
Job Shop Appliancerepair
Emergencyroom
Batch Commercialbakery
ClassroomLecture
Repetitive Automotiveassembly
Automaticcarwash
Continuous(flow)
Oil refineryWater purification
Product – Process Matrix
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Fixed automation: Low production cost and high volume but withminimal variety and high changes cost – Assembly line
Programmable automation: Economically producing a wide
variety of low volume products in small batches – Computer-aided design and manufacturing systems (CAD/CAM) – Numerically controlled (NC) machines / CNC – Industrial robots (arms)
Flexible automation: Require less changeover time and allowcontinuous operation of equipment and product variety – Manufacturing cell – Flexible manufacturing systems: Use of high automation to achieve
repetitive process efficiency with job shop process• Automated retrieval and storage• Automated guided vehicles
– Computer-integrated manufacturing (CIM)
and control devices that enables it to
operate
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Robot
Show wafer_handler_web
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Flexible Manufacturing System
• Group of machines that include supervisory computer control, automatic material handling, robots and other processing equipment – Advantage:
reduce labor costs and more consistent qualitylower capital investment and higher flexibility than
hard automation
relative quick changeover time
– Disadvantageused for a family of products and require longer planning and development times
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Computer-integrated manufacturing
• Use integrating computer system to link a broad
range of manufacturing activities, including
engineering design, purchasing, order processing
and production planning and control• Advantage:
rapid response to customer order and product
change, reduce direct labor cost, high quality
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• Layout : the configuration of departments, workcenters, and equipment, – Whose design involves particular emphasis on
movement of work (customers or materials) through thesystem
• Importance of layout – Requires substantial investments of money and effort
– Involves long-term commitments
– Has significant impact on cost and efficiency of short-term operations
Layout
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Inefficient operations
For Example:
High Cost
Bottlenecks
Changes in the design
of products or services
The introduction of newproducts or services
Accidents
Safety hazards
The Need for Layout Decisions
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Changes inenvironmental
or other legal
requirements
Changes in volume of
output or mix of
products
Changes in methodsand equipment
Morale problems
The Need for Layout Design (Cont’d)
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Basic Layout Types
• Product Layout – Layout that uses standardized processing operations
to achieve smooth, rapid, high-volume flow• Auto plants, cafeterias
• Process Layout – Layout that can handle varied processing requirements
• Tool and die shops, university departments
• Fixed Position Layout
– Layout in which the product or project remainsstationary, and workers, materials, and equipment aremoved as needed
• Building projects, disabled patients at hospitals
• Combination Layouts
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A Flow Line for Production or Service
Flow Shop or Assembly Line Work Flow
Raw materialsor customer FinisheditemStation2 Station3 Station4
Material
and/or
labor
Station1
Material
and/or
labor
Material
and/or
labor
Material
and/or
labor
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A U-Shaped Production Line
Advantage: more compact, increased communication
facilitating team work, minimize the material handling
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Process Layout
Process Layout - work travels
to dedicated process centers
Milling
Assembly
& Test
Grinding
DrillingPlating
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Layout types: Product or Process Make your pick
A
B
A
B
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Process vs Layout types
• Job Shop
• Project
• Repetitive
• Product
• Process
• Fixed-point
Match
?
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Product layout
Advantages – High volume
– Low unit cost
– Low labor skill needed
– Low material handling
– High efficiency andutilization
– Simple routing and
scheduling – Simple to track and
control
Disadvantages
– Lacks flexibility
• Volume, design, mix
– Boring for labor
• Low motivation• Low worker enrichment
– Can not accommodate partial
shut downs/breakdowns
– Individual incentive plans are
not possible
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Cellular Layouts
• Cellular Manufacturing – Layout in which machines are grouped into a cell that
can process items that have similar processingrequirements. A product layout is visible inside each
cell.• Group Technology
– The grouping into part families of items with similar design or manufacturing characteristics. Each cell isassigned a family for production. This limits theproduction variability inside cells, hence allowing for aproduct layout.
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A Group of Parts
Similar manufacturing characters
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Process Layout
Gear
cutting
Mill Drill
Lathes
Grind
Heat
treat
Assembly
111
333
222
444
222
111
444
111 33311112222
222
3333
111
444
111
3 3 3 3 3 3 3 3 3
4 4 4 4 4
3 3 3 3 3 3
2 2 2 2 2
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Cellular Manufacturing Layout
-1111 -1111
222222222 - 2222
A s s e m
b l y
3333333333 - 3333
44444444444444 - 4444
Lathe
Lathe
Mill
Mill
Mill
Mill
Drill
Drill
Drill
Heat
treat
Heat
treat
Heat
treat
Gear
cut
Gear
cut
Grind
Grind
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Basic Layout Formats
Part Family W Part Family X
Part Family Y
Part Family Z
Assemble Y,W Assemble X,Z
FinalProduct
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Fixed-Position and combination Layout
• Fixed-Position Layout:
item being worked on remains stationary,
and workers, materials and equipment aremoved as needed.
Example: buildings, dams, power plants
• Combination Layouts:combination of three pure types.
Example: hospital: process and fixed position.
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Location Decision
Location decision requires when-
1.A new unit to be set up
2.Poor selection earliar
3.Change of govt. policy
4.Growth of business makes it advisable
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Location decision
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Techniques for location decision
QuantitativeCentre of gravity model
Median Model
Brown and Gibson ModelDimensional Analysis
Qualitative
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