Systematic Layout Systematic Layout y yPlanning

y yPlanning

References1 Richard L Francis Facility Layout and1. Richard L. Francis, Facility Layout and

Location: An Analytical Approach

2 S K Sharma Industrial engineering and2. S.K. Sharma, Industrial engineering and

operations management.

3 Daniel Kitaw Industrial Management and

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3. Daniel Kitaw, Industrial Management and

Engineering Economy.

SYSTEMATIC LAYOUT PLANNING (SLP)SYSTEMATIC LAYOUT PLANNING (SLP)

The most popular approach used in designing

l t l tplant layout.

Th p d h s b n ppli d t The procedure has been applied to

production, transportation, storage,pro uct on, transportat on, storag ,

supporting services, and office activities,

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among others.

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CONT’D CONT’D Information gathering Flow analysis + Activity analysis Relationship diagram

Space consideration + Relationship diagram Space consideration + Relationship diagram Space relationship diagram

Modifying consideration + Practical limitation A number of alternative layouts are designed and

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y gevaluated

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INFORMATION GATHERING INFORMATION GATHERING

Information is required pertaining to the

d t d h d lproduct, process, and schedule.

D t di p d t d si d isi s Data regarding product design decisions can

affect the layout significantly.affect the ayout s gn f cant y.

The product design decisions can directly or

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p g yindirectly affect the layout.

Basic product design data can be obtained formCONT’D CONT’D

Basic product design data can be obtained form

photographs of the product, exploded drawings,

engineering drawings of individual parts, parts lists,

bill of materials and assembly chartsbill of materials and assembly charts.

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CONT’D CONT’D

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CONT’D CONT’D

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CONT’D CONT’D Company open-close valve company Prepared by Jhon Mc Franciesp y p p y p y J F

Product gate valve Date October 31, 19xx

Part No.

PartName

Drawing No.

No. Unit Materials Size Make Buy

0105 Nut 2005 1 Brass Buy0105 Nut 2005 1 Brass Buy

0204 Washer 2003 1 Aluminum 0.8”odx0.22”idx0.01” thick Buy

0303 Handle 1010 1 Zinc, die casting 2.0”x0.6” Make

0501 Cap 1008 1 Brass, hex bar stock 0.75”x0.40” Make

0601 Packing 2001 1 Rubber 0.58”odx0.25”idx0.25” Buy

0702 Ferrule 1007 1 Brass, tube 0.4”x0.2” Make

0802 Stem 1000 1 Brass, rod 3.0”x0.375” Make

0901 B hi 1004 1 B 1 1” 1 5” M k0901 Bushing 1004 1 Bronze 1.1”x1.5” Make

1001 Gasket 2007 1 Rubber 1.4”odx1.17”idx0.025” Buy

1101 Gate 1006 1 Bronze 1.2”x0.96”x0.55” Make

1305 Body 1002 1 Bronze 1.4”x1.9”x2.125” Make

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1402 Box 2011 1 Cardboard 2.125”x2.125”x4.25” Buy

1503 Staple 2012 4 Aluminum Buy

1603 Label 2013 1 Adhesive backed paper 2.0”x1.0” Buy

Company open-close valve company Prepared by Jhon Mc Francies

Product gate valve Date October 31, 19xx

Level Part No. Part Name Drawing No. No. Unit Make Buy Comments

0 0010 Pipe valve 0010 1 Make0 0010 Pipe valve 0010 1 Make

1 0100 Bottom assembly 0020 1 Make

2 0200 Top assembly 0030 1 Make

4 0105 Nut 2005 1 Buy

3 0204 Washer 2003 1 Buy

2 0303 Handle 1010 1 Make

3 0403 Paint - 0.010 oz. Buy

4 0501 Cap 1008 1 Make

5 0601 Packing 2001 1 Buy

3 0702 Ferrule 1007 1 Make

1 0802 Stem 1000 1 Make

2 0901 Bushing 1004 1 Make2 0901 Bushing 1004 1 Make

3 1001 Gasket 2007 1 Buy

2 1101 Gate 1006 1 Make

2 1201 Grease - 0.001 oz. Buy

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3 1305 Body 1002 1 Make

6 1402 Box 2011 1 Buy

7 1503 Staple 2012 4 Buy

7 1603 Label 2013 1 Buy

CONT’D CONT’D

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CONT’D CONT’D ♦ The assembly chart is an analog model of the

operations and inspections required in assembling ap p q g

product.

♦ Assembly chart shows graphically which parts must

go into(or be assembled to) other partsgo into(or be assembled to) other parts.

♦ The assembly chart is the basis for the layout of the

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assembly department or assembly lines.

CONT’D CONT’D ♦ Process design decisions determine whether a part

will be purchased or produced, how the production ofp p , pparts will be achieved, what equipment will be used,

d h l ll k f hand how long it will take to perform the operation.

♦ Such information is typically summarized on an♦ Such information is typically summarized on an

operation sheet or route sheet.

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CONT’D CONT’D C P d b J M FCompany open-close valve company Prepared by Jhon Mc Francies _ _

Product gate valve Date October 31, 19xx _

Part name Bushing Part Number 0901 _

Material Bronze casting Production Quantity 1500 _

Op. No. Op. Description Machine type Tooling an d supplies Setup time (hrs) Op. time

05 Cast: using green sand mold with 50 bushingsper mold; pour, cool, cut off gates and risers

Bench moldBand saw

T- shaped dry sand core for each bushing

0.50 2.00

06 Clean: grind, as needed to remove flashing, and tumble

Bench or pedestal grinder; tabling barrel

A-24-M-8-V type grinding wheel

0.25 0.75 and tumble grinder; tabling barrel grinding wheel

07 Drill hole:3/16”x1/2” Turret lathe 3/16” drill 0.50 2.5o

08 Bore hole: 7/16”x1/4” Turret lathe 7/16” bore - 2.75

09 Turn: small end to 5/8” large end to 3/2” and then large end to 5/4”

Turret lathe Round-nose turning tool, cut off tool and right hand

- 10.50then large end to 5/4 cut-off tool and right-hand

facing tool

10 Thread: small and large ends (5/8”-16 UNC-2A and 5/4”-16 UNC-2A threads)

Turret lathe Stationary, self-opening die heads for 5/8” and 5/4”

- 9.25

T t l 1 25 27 75

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Total 1.25 27.75

Comments: Operations 7 through 10 are performed on the same turret lathe, using one setup. The operating times given include rechecking the work piece. The operations are performed as follows: chuck large end; drill, bore, turn, thread, and cutoff small end to length; chuck small end, grip hexagonal surface; turn large end to 1.50” over 0.375” length, cutoff to length, turn large end to 1.25” over 0.25” length, retaining 1.50” diameter over 1.25” length.

CONT’D CONT’D ♦ The operation process chart is often used to

supplement the route sheet; in a sense, it is a pictorialpp , p

representation of the route sheet.

♦ Its an expansion of the assembly process chart in that

it includes all operations and inspections performed onit includes all operations and inspections performed on

the product.

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♦ The basis for the layout of a manufacturing plant.

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♦ A precedence diagram establishes the prerequisite

CONT’D CONT’D ♦ A precedence diagram establishes the prerequisite

assembly steps that must be completed beforeperforming a given assembly step.perform ng a g ven assembly step.

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CONT’D CONT’D

♦ Schedule design decisions tell us how much to produce

and when to produceand when to produce.

♦ Production schedules are given using an analog modelg g g

called Gantt chart.

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CONT’D CONT’D

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CONT’D CONT’D ♦ Most information sources available portray yesterdays

and, possibly today’s data., p y y

♦ We are interested in tomorrow's data, since we are

developing a solution to be used tomorrow.

D h i h i l i hi♦ Data sources emphasizes the interrelationships among

product, process, schedule, and layout design.

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p p y g

♦ The layout must support the objectives of the facility.

CONT’D CONT’D ♦ The effective arrangement of personnel and

equipments depends on accurate information regardingq p p g g

product, process, and schedule requirements.

♦ When such requirements change rapidly, it is

important for the layout to accommodate changes inimportant for the layout to accommodate changes in

requirements.

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FLOW ANALYSIS AND ACTIVITY ANALYSISFLOW ANALYSIS AND ACTIVITY ANALYSIS

Flow analysis concentrates on some

tit ti f t b tquantitative measures of movement between

departments or activities.departments or activities.

Activity analysis is concerned with the non- ct ty ana ys s s concerned w th the non

quantitative factors that influence the

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location of departments or activities.

CONT’D CONT’D

♦ Basic data have been obtained concerning the process,

d t d s h d l th l t l st is i sitiproduct and schedule, the layout analyst is in position

to analyze the flow of materials, equipment, and

personnel.

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Factor that affect the flow pattern given by Apple:

CONT’D CONT’D Factor that affect the flow pattern given by Apple:

1. External transportation facilities2. Number of parts in product3. Number of operations on each part4. Sequence of operations on each part5. Number of subassemblies5. Number of subassemblies6. Number of units to be produced7 Necessary flow between work areas

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7. Necessary flow between work areas8. Amount and shape of space available

9 Influence of process

CONT’D CONT’D 9. Influence of process10. Types of flow pattern11 P d f l11. Product versus process type of layout12. Location of service areas13. Production department location14. Special requirement of departmentsp q p15. Material storage16 Desired flexibility

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16. Desired flexibility17. The building

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CONT’D CONT’D Types of Flow Patterns

♦ Flow patterns can be classified either horizontal or♦ Flow patterns can be classified either horizontal or

vertical.

♦ There are at least five basic types of horizontal flow

ttpatterns.

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CONT’D CONT’D

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CONT’D CONT’D

♦ Vertical flow pattern exist both in single-story and

multistory buildings. Utilization of overhead space has

focused great attention on the design of vertical flowf g g f f

pattern.

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CONT’D CONT’D

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CONT’D CONT’D Types of layout

♦ The choice of layout type is the factor affecting the♦ The choice of layout type is the factor affecting the

flow pattern.

♦ There are four general types of layout categories:1 P d t l t1. Product layout2. Process layout3 F d d

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3. Fixed position and,4. Combination layout

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CONT’D CONT’D Flow analysis approach

♦ Flow process chart♦ Flow process chart

♦ Multiproduct process chartp p

♦ Flow diagram

♦ From-to-chart

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CONT’D CONT’D

Flow process chart

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CONT’D CONT’D

Multiproduct process chart

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CONT’D CONT’D

Flow diagram

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CONT’D CONT’D

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ACTIVITY RELATIONSHIP ANALYSIS ACTIVITY RELATIONSHIP ANALYSIS

• Flow analysis tends to relate various activities on some

quantitative basisquantitative basis.

• Typically, the relationship is expressed as a functionyp y, p p

of transport cost or material handling cost.

• There might be other qualitative aspects of layout

design that might be important

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design that might be important.

CONT’D CONT’D l h hRelationship chart

• A relationship chart is a triangular matrix whoseA: Absolutely necessary• A relationship chart is a triangular matrix whose

elements represent the relationships among plant

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E: Especially important

I: Importantlayout departments.

L tt d l d t t d i bl

I: Important

O: Ordinary closeness OK

• Letter codes are also used to represent desirable or

undesirable levels of closeness between departments.

U: Unimportant

X: Undesirable

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p

Th l h h (REL h )

CONT’D CONT’D • The activity relationship chart (REL chart) was

developed to facilitate the consideration of qualitativep q

factors – analytically!

• The REL chart replaces the numbers in the Travel

chart by a qualitative closeness ratingchart by a qualitative closeness rating.

• All pairs of relationships are evaluated, and a closeness

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rating (A, E, I, O, U, and X) is assigned to each pair.

CONT’D CONT’D

• With the exception of U rating, the reason for the

assigned rating is indicated using a numeric code.

• Closeness ratings represent an ordered preference

for “closeness”.

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CONT’D CONT’D

• Specifically, A and X ratings are considered to be

most important ratingsmost important ratings.

• Hence, any layout must satisfy A and X ratings.Hence, any layout must satisfy A and X ratings.

• Thus, A and X > E > I > O > U , where > means “more

important or higher ranking than.”

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Rule of thumb:

CONT’D CONT’D Rule of thumb:

• Very few A and X relationships should be assigned.( th 5% f th l ti t b A(no more than 5% of the closeness ratings to be an Aand X).N h 10% h ld b E• No more than 10% should be an E.

• No more than 15% to be an I.• No more than 20% to be an O.• Which means that about 50% of the relationships

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Which means that about 50% of the relationshipsshould be U.

Bl k l bl k l t d l d fi t b

CONT’D CONT’D • Block plans, or block layouts are developed first by

determining the sizes, shapes and relative locations of

departments or other designated activities.

• Next, detailed layouts are designed for each

departmentdepartment.

• Thus different REL charts are needed for designing

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block plans and detailed layouts.

CONT’D CONT’D

• The process of constructing an activity relationship

chart can be complicated by the presence of multiple

relationships that will influence the design of the

layout.

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CONT’D CONT’D

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CONT’D CONT’D

• The relationship chart and the numerically weightedratings, assigned to the closeness values, are the basisrat ngs, ass gned to the closeness alues, are the bas s

for the order and placement in which departments

enter the layout.

• The ratings assigned for A E I O U and X are used to• The ratings assigned for A,E,I,O,U and X are used to

calculate the Total Closeness Rating (TCR) for each

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department.

CONT’D CONT’D

m ... 1 = i );rV( = TCR ij

n

1=ji

Where

1=j

TCRj = Total Closeness Rating for department;

V(rij) = Numerical value assigned to the closeness value for

department i and j.

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n = Total number of departments.

CONT’D CONT’D

• The first department to be placed in the layout is

assigned by taking the department with the greatestassigned by taking the department with the greatestTCR.

• Next, the relationship chart is scanned to see if there

i d t t th t h A l ith this any department that has an A value with the

department already placed.

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CONT’D CONT’D

• If no A value exists, a check is made for E value, and

if no E value appears a check is made for I valueif no E value appears, a check is made for I value,

followed by O value.

• If ties develop, the department having the greatest

TCR i h Thi i i ll d ilTCR is chosen. This process is continually used until

finally all departments are placed in the layout.

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y p p y

Example Example

Numerical values

A = 10,000; E = 1,000;I = 100; O = 10; U = 0; andX = -10,000

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CONT’D CONT’D

a dcb

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CONT’D CONT’D

hh

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REL DiagramCONT’D CONT’D

REL Diagram

• From REL chart, we construct activity relationshipy p

diagram (REL diagram).

• The purpose is to depict spatially the relationships of

the activitiesthe activities.

• The basic premise is that geographic proximity can be

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used to satisfy particular relationships.

CONT’D CONT’D

• For example, when the activity relationships reflect

the magnitudes of material flows pairs of activitiesthe magnitudes of material flows, pairs of activities

having the greatest pair wise flow are located next to

each other.

Si il l i f i i i h i A i• Similarly, pairs of activities having an A rating are

located adjacently.

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CONT’D CONT’D

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SPACE REQUIREMENT AND AVAILABILITY SPACE REQUIREMENT AND AVAILABILITY

The bases for determining the space requirement:

i. Production rate

ii E ipm nt i m ntii. Equipment requirement

iii.Employee requirementiii.Employee requirement

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Commonly used methods of determining space

CONT’D CONT’D Commonly used methods of determining space

requirement:

i. Production center method

• Consists of a single machine plus all the associated

equipment and space required for its operationsequipment and space required for its operations.

• Work space, maintenance space, and storage space

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p , p , g p

are added to space requirement for the machine.

CONT’D CONT’D

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ii Roughed out layout method

CONT’D CONT’D ii. Roughed-out layout method

• Templates or models are placed on the layout top p y

obtain an estimate of the general configuration and

space requirements.

iii Space standards methodiii. Space standards method

• Industry standards can be used to determine the

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space requirement.

CONT’D CONT’D

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D i i th l ti hi di

DESIGNING THE LAYOUT DESIGNING THE LAYOUT Designing the space relationship diagram

• The over all layout is designed by first combining theThe over all layout is designed by first combining the

space consideration with the REL diagram.

• For each activity, a space template is constructed, to

scale t represent the size and shape f the activityscale, to represent the size and shape of the activity.

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ExampleExample

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CONT’D CONT’D

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• After construction the space relationship diagram the

CONT’D CONT’D • After construction the space relationship diagram, the

space templates are modified and adjusted and the

relative locations of the activities are shifted as

necessary to accommodate practical limitations andnecessary to accommodate practical limitations andother considerations.

• The block plan is a scaled diagrammatic representation

f th b ildi ll h th l ti f i t l4 - 63

of the building normally shows the locations of internalpartitions and columns.

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CONT’D CONT’D Presenting the layout

• A number of alternative component designs a number• A number of alternative component designs, a number

of alternative overall designs, or a number of

alternative detailed designs should have been

generatedgenerated.

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CONT’D CONT’D

There are three methods of visually representing layouts

• Drawing or sketches

T di si l i i d ls• Two-dimensional iconic models

• Three-dimensional iconic modelsThree dimensional iconic models

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CONT’D CONT’D

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CONT’D CONT’D Selection, implementation and follow-up

• Select the design from alternatives which best meets• Select the design from alternatives which best meets

your objective.

• The design selected must be specified, all concerned

b ld d h l b i ll dmust be sold, and the layout must be installed,

observed, and periodically evaluated in an operating

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p y p g

environment.