LAYOUT TYPES• PRODUCT

• PROCESS CELLULAR(Group Technology)

• MIXED A D EB C F

• LAYOUT BY FIXED POSITION

- Ship building

- Special Structures

LINKS AMONG PRODUCT, PROCESS, SCHEDULE AND LAYOUT DESIGN

PRODUCTDESIGN

LAYOUTDESIGN

SCHEDULEDESIGN

PROCESSDESIGN

PRODUCT LAYOUT1. Smooth and logical flow lines

2. Small in process inventories.

3. Total production time/unit short.

4. Reduced material handling

5. Little operator skill, training simple

6. Simple production planning & control

7. Less space for work in transit and temporary

1 2 3 n

INPUT FINAL OUTPUT

A

B C D

F

E

A

B C D E

FG

H

P - Q CHART

Product Layout

Combination Layout

Process Layout

Q

Quantity to be Made

P (No. of Products or “VARIETY”

INPUT DATA & ACTIVITES

1. Flow of Materials 2. Activity Relationship

3. Relationship Diagram

4. Space Reqd. 5. Space Available

6. Space Relationship Diagram

7. Modifying Considerations

9. Development Layout Alternatives

10. Evaluation

8. Practical Limitation

An

alys

isS

ear

chS

ele

ctio

n

1

Raw mtl.

3

5

1

Saw Lathe-1 Drill Inspect -1Mill

21

78

11 12 13 14

Fin. goods Packing Inspect-26

4

2

15

10

6

4

3

2 5 4 3

9

Lathe-2

16’ 16’ 16’ 16’ 16’ 16’

24’

16’

24’

16’

Operation

Inspection

Storage

5

Raw mtl.

3

1

11

Saw Lathe Drill Mill

7

119

Fin. goods Packing Inspection6

4

2

6

10

15

2

3

4

5 4

12 13 14

2

8

1

3

TABLE 1 EXAMPLE PROCESSING SEQUENCES FOR THREE PRODUCTS

Product Processing Sequence

A

B

C

Saw, mill, inspect, turn, mill,drill, inspect, package

Drill, turn, mill, inspect, package

Saw, turn, drill, mill, inspect,package

Table 2. FLOW RATES FOR THE PRODUCTS CONSIDERED IN TABLE 1

Product Flow Rate (pallet loads/day)

A

B

C

8

3

5

As such, the construction of a from-to chart

is a convenient means of reducing a large

volume of data into a workable from. By

inspecting the data displayed in the from-to

chart, the layout analyst can identify the

departments having large volumes.

To From

R.M. Saw Lathe Drill Mill Ins. Pkg. F.G.

R.M 13 3

Saw 5 8

Lathe 5 11

Drill 3 5 8

Mill 8 16

Ins. 8 16

Pkg. 16

F.G.

Fig 2 From-to chart showing number of materials handling trips per day between departments.

Normally, the from-to chart is used to

analyze the flow in process layouts. The

item movement that occurs over some

specified period of time is totaled for all

products and entered in the from-to chart.

Figure 3

To From

R.M. Saw Lathe Drill Mill Ins. Pkg. F.G.

R.M 16 40 72 88 60 36 20

Saw 16 24 56 72 44 20 36

Lathe 40 24 32 48 20 44 60

Drill 72 56 32 16 36 60 76

Mill 88 72 48 16 52 76 92

Ins. 60 44 20 36 52 24 40

Pkg. 36 20 44 60 76 24 16

F.G. 20 36 60 76 92 40 16

To From

R.M. Saw Lathe Drill Mill Ins. Pkg. F.G. Total

R.M 208 216 424

Saw 120 576 696

Lathe 160 528 688

Drill 96 80 288 464

Mill 128 832 960

Ins. 160 384 544

Pkg. 256 256

F.G. 0

Total 0 208 376 504 1184 1120 384 256 4032

1 Office2 Foreman3 Conference room4 Parcel post5 Parts shipment6 Repair and service parts7 Service area8 Receiving9 Testing10 General storage

O4

U U U 12

U U 12

U 12

U

I5

OU

E3

U U U

U 14

A1

U U

E3

A1

E5

O4

UU

UU

U

O4

U

U

E3

3

12

U

U

U

U

11

12

U

O2

Code

1

2

3

4

5

6

7

8

9

10

Reason

Flow of materials

Ease of supervision

Common personnel

Contact necessary

Convenience

Rating Definition

A

E

I

O

U

X

Absolutely

Especially Important

Important

Ordinary closeness OK

Unimportant

Undesirable

Fig.:5 Activity relationship

chart

5 8 7

10 9 6

4 2 3

1

Legend

A Rating

E Rating

I Rating

O Rating

U Rating

X Rating

Table 3 Production Space Requirements

Process Equipment No.

MachineCenter

DimensionsPer Machine

(ft)Depth Width

MachineCenter

Area perMachine

(ft2)

TotalProcess

Area(ft2)

Saw Armstronghack saw

3 10 x 9 190 570

Mill K & Tplain millVerticalmillHand mill

57

4

13.5 x 10.511 x 10.25

7.25 x 9.75

142113

71

710791

284

Cont…..

Process Equipment No.

MachineCenter

DimensionsPer Machine

(ft)Depth Width

MachineCenter

Area perMachine

(ft2)

TotalProcess

Area(ft2)

Drill 2 Spindle Avey1 Spindle Delta6 Spindle Delta

221

8.25 x 6.57.5 x 4.57.45 x 10.5

543482

1086882

Turn GisholtMonarchHardingeW & S turretB & Sautomatic

1211

1

9.25 x 17.7514 x 6.259.5 x 58.5 x 20.25

7.5 x 15.5

1648848173

116

16417648173

116

Cont…..

Process

Equipment

No.

Machine Center

Dimensions Per Machine

(ft) Depth Width

Machine Center

Area per Machine

(ft2)

Total Process

Area (ft2)

Form Gas furnance Arbor press X

1 8 x 7

56 56

Paint Dip tank Spray booth

2 1

7 x 12 9 x 11

84 99

168 99

Clean Tumble 1 7 x 6 42 42

Assemble Bench Bench Avey drill

1 1 2

8 x 7 8 x 7 8.25 x 6.5

56 56 54

56 56 108

Packaging Bench 1 8 x 7 56 56

Total square feet required 40 % aisle space

Production space required

3,931 1,572 5,503

Table 4 Nonproduction activity space requirementsActivity Area (ft2)

Storage Warehouse Other Office Main Office Hallway Rest rooms Locker rooms Men Women Foreman Desk Maintenance Desk Parts Tool crib Receiving and shipping Total space required

180 180

500 120 100

84 60

24

20 80 50 50

1,448

To the 5,503 square feet of floor for

production, we must add the 1,448 square

feet shown in Table 4 to give an estimate of

6,951 square feet of floor space required in

total.

5(500)

8(200)

10(1,750)

7(575)

9(500)

6(75)

4(350)

2(125)

3(125)

1(1,0)

Designing the Layout

10

6

2

3

9

785

1

4

80’

65’

The Plant Layout Problem

SUMMARY

• Objectives in different kinds of Layout– Process, Product, Mixed

• Systematic Layout Planning for Process Layouts

• From to charts to measure material handling effort

• Step by Step procedure for a sample layout• A precursor to Computerized Layout

Planning