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Facilities Planning Facilities Planning - Unit 04- Unit 04
Layout Types: ManufacturingLayout Types: Manufacturing
Layout Types: Manufacturing - 2
Hierarchy of Facility PlanningHierarchy of Facility PlanningLayout DesignLayout Design
Facility Planning
Structural Design
Facility Location
Facility Design
Handling System Design
Layout Design
Source for Figure: Tompkins and White, Facilities Planning, 2nd edition, Wiley
Layout Types: Manufacturing - 3
Layout DesignLayout Design
Facility layoutFacility layout means planning: for the location of all machines, utilities, employee
workstations, customer service areas, material storage areas, aisles, restrooms, lunchrooms, internal walls, offices, and computer rooms
for the flow patterns of materials and people around, into, and within buildings
Layout Types: Manufacturing - 4
Layout DesignLayout DesignPlanning for required Spaces and AreasPlanning for required Spaces and Areas
Equipment Work stations Material storage Rest/break areas Utilities Eating areas Aisles Offices
Layout Types: Manufacturing - 5
Location of these various areas impacts the flow through the system.
The layout can affect productivity and costs generated by the system.
Layout alternatives are limited by the amount and type of space required for the
various areas the amount and type of space available the operations strategy
Layout Design – Layout Design – IntroductionIntroduction Characteristics of the Facility Layout Decision Characteristics of the Facility Layout Decision
Layout Types: Manufacturing - 6
Basic Layout TypesBasic Layout Types
Product Layouts Process Layouts Fixed-position layouts Cellular/Group technology layouts
Layout Types: Manufacturing - 7
Basic Layout TypesBasic Layout TypesProduct Volume vs. Product VarietyProduct Volume vs. Product Variety
Low Medium High
High
Medium
Low
Product Planning
Department
Fixed Materials Location Planning
Department
Process Planning
Department
Product Family Planning
Department
Product Layout
Fixed Location Layout
Group Technology Layout
Process LayoutVolu
me
Variety
Layout Types: Manufacturing - 8
Types of LayoutTypes of LayoutFixed Position LayoutFixed Position Layout
Lathe Press Grind
Weld AssemblyPaint
Storage
Warehouse
Layout Types: Manufacturing - 9
Types of LayoutTypes of LayoutFixed Position LayoutFixed Position Layout
Layout in which the product or project remains stationary, and
workers, materials, and equipment are moved as needed.
Examples:Examples:
Large construction projects (buildings, power plants, dams)
Shipbuilding, production of large aircraft
Rockets used to launch space missions
Layout Types: Manufacturing - 10
Types of LayoutTypes of LayoutFixed Position Layout: AdvantagesFixed Position Layout: Advantages
Material movement is reduced. Promotes job enlargement by allowing
individuals or teams to perform the “whole job”.
Continuity of operations and responsibility results from team.
Highly flexible; can accommodate changes in product design, product mix, and product volume.
Independence of production centers allowing scheduling to achieve minimum total production time.
Layout Types: Manufacturing - 11
Increased movement of personnel and equipment.
Equipment duplication may occur. Higher skill requirements for personnel. General supervision required. Cumbersome and costly positioning of
material and machinery. Low equipment utilization.
Types of LayoutTypes of LayoutFixed Position Layout: LimitationsFixed Position Layout: Limitations
Layout Types: Manufacturing - 12
Drill Grind Drill
Lathe
Drill
Drill
Storage
Warehouse
Assembly
Lathe
Bend
Lathe
Mill
Press
Drill
Types of LayoutTypes of LayoutProduct Type LayoutProduct Type Layout
Layout Types: Manufacturing - 13
Types of LayoutTypes of LayoutProduct Type Layout - RequirementsProduct Type Layout - Requirements
Standardized product High production volume Stable production quantities Uniform quality of raw materials & components
Layout Types: Manufacturing - 14
Types of LayoutTypes of LayoutProduct Type Layout - AssumptionsProduct Type Layout - Assumptions
Volume is adequate for high equipment utilization Product demand is stable enough to justify high
investment in specialized equipment Product is standardized or approaching a phase of its
life cycle that justifies investment in specialized equipment
Supplies of raw materials and components are adequate and of uniform quality ensure they will work with specialized equipment
Layout Types: Manufacturing - 15
Since the layout corresponds to the sequence of operations, smooth and logical flow lines result.
Since the work from one process is fed directly into the next, small in-process inventories result.
Total production time per unit is short. Since the machines are located so as to minimize
distances between consecutive operations, material handling is reduced.
Little skill is usually required by operators at the production line; hence, training is simple, short, and inexpensive.
Simple production planning control systems are possible.
Less space is occupied by work in transit and for temporary storage.
Types of LayoutTypes of LayoutProduct Type Layout - AdvantagesProduct Type Layout - Advantages
Layout Types: Manufacturing - 16
A breakdown of one machine may lead to a complete stoppage of the line that follows that machine.
Since the layout is determined by the product, a change in product design may require major alternations in the layout.
The “pace” of production is determined by the slowest machine.
Supervision is general, rather than specialized. Comparatively high investment is required, as
identical machines (a few not fully utilized) are sometimes distributed along the line.
Types of LayoutTypes of LayoutProduct Type Layout - LimitationsProduct Type Layout - Limitations
Layout Types: Manufacturing - 17
Lathe Drill Weld
Mill
Drill
Grind
Storage
Warehouse
Lathe
Lathe
Mill
Mill
Lathe
Mill
Paint
Grind
Assembly
Assembly
Paint
Weld
Types of LayoutTypes of LayoutProcess Type LayoutProcess Type Layout
Layout Types: Manufacturing - 18
Process type layouts can handle varied processing requirements
The layouts feature departments or other functional groupings in which similar kinds of activities are performed
Examples:Examples: Machine shops usually have separate departments for milling, grinding, drilling, and so on
Different products may present quite different processing requirements and sequences of operations
Types of LayoutTypes of LayoutProcess Type LayoutProcess Type Layout
Layout Types: Manufacturing - 19
Process Layout - work travels to dedicated process centers
Milling
Assembly Test Grinding
Drilling Plating
Types of LayoutTypes of LayoutProcess Type LayoutProcess Type Layout
Layout Types: Manufacturing - 20
A high degree of flexibility exists relative to equipment or manpower allocation for specific tasks.
Comparatively low investment in machines is required.
The diversity of tasks offers a more interesting and satisfying occupation for the operator.
Types of LayoutTypes of LayoutProcess Type Layout - AdvantagesProcess Type Layout - Advantages
Layout Types: Manufacturing - 21
Since longer flow lines usually exist, material handling is more expensive.
Production planning and control systems are more involved.
Total production time is usually longer. Comparatively large amounts of in-process
inventory result. Space and capital are tied up by work in
process. Because of the diversity of the jobs in
specialized departments, higher grades of skill are required.
Types of LayoutTypes of LayoutProcess Type Layout - LimitationsProcess Type Layout - Limitations
Layout Types: Manufacturing - 22
Types of LayoutTypes of LayoutProcess Layout vs. Product LayoutProcess Layout vs. Product Layout
Layout Types: Manufacturing - 23
Drill Grind Assembly
Drill
Weld
Assembly
Storage
Warehouse
Lathe
Assembly
Grind
Press
Mill
Lathe
Paint
Drill
Drill
Press
Grind
Assembly
Types of LayoutTypes of LayoutGroup Technology/Cellular/Product Family LayoutGroup Technology/Cellular/Product Family Layout
Layout Types: Manufacturing - 24
Group Technology (GT) is a management philosophy that attempts to group products with similar design or manufacturing characteristics, or both.
Cellular Manufacturing (CM) is an application of GT that involves grouping machines based on the parts manufactured by them.
The main objective of CM is to identify machine cells and part families simultaneously, and to allocate part families to machine cells in a way that minimizes the intercellular movement of parts.
Types of LayoutTypes of LayoutGroup Technology vs. Cellular ManufacturingGroup Technology vs. Cellular Manufacturing
Layout Types: Manufacturing - 25
Original Process LayoutOriginal Process Layout
CA B Raw materials
Assembly
1
2
3
4
5
6 7
8
9
10
11
12
Types of LayoutTypes of LayoutGroup Technology/Cellular Layout – Example A (page 1)Group Technology/Cellular Layout – Example A (page 1)
Layout Types: Manufacturing - 26
Original Part Routing MatrixOriginal Part Routing Matrix
Types of LayoutTypes of LayoutGroup Technology/Cellular Layout – Example A (page 2)Group Technology/Cellular Layout – Example A (page 2)
MachinesParts 1 2 3 4 5 6 7 8 9 10 11 12
A x x x x xB x x x xC x x xD x x x x xE x x xF x x xG x x x xH x x x
Layout Types: Manufacturing - 27
Reordered Part Routing MatrixReordered Part Routing Matrix
Types of LayoutTypes of LayoutGroup Technology/Cellular Layout – Example A (page 3)Group Technology/Cellular Layout – Example A (page 3)
MachinesParts 1 2 4 8 10 3 6 9 5 7 11 12
A x x x x xD x x x x xF x x xC x x xG x x x xB x x x xH x x xE x x x
Layout Types: Manufacturing - 28
Revised Cellular LayoutRevised Cellular Layout
Types of LayoutTypes of LayoutGroup Technology/Cellular Layout – Example A (page 4)Group Technology/Cellular Layout – Example A (page 4)
3
6
9
Assembly
12
4
8 10
5
7
11
12
A B CRaw materials
Cell 1 Cell 2 Cell 3
Layout Types: Manufacturing - 29
Types of LayoutTypes of LayoutGroup Technology/Cellular Layout – Example B (page 1)Group Technology/Cellular Layout – Example B (page 1)
Unorganized Parts
Layout Types: Manufacturing - 30
Process Flows before the Use of GT Cells
Types of LayoutTypes of LayoutGroup Technology/Cellular Layout – Example B (page 2)Group Technology/Cellular Layout – Example B (page 2)
Layout Types: Manufacturing - 31
Transition from Process Layout
Types of LayoutTypes of LayoutGroup Technology/Cellular Layout – Example B (page 3)Group Technology/Cellular Layout – Example B (page 3)
1. Grouping parts into families that follow a common sequence of steps.
2. Identifying dominant flow patterns of parts families as a basis for location or relocation of processes.
3. Physically grouping machines and processes into cells.
Layout Types: Manufacturing - 32
Grouping parts into families
Types of LayoutTypes of LayoutGroup Technology/Cellular Layout – Example B (page 4)Group Technology/Cellular Layout – Example B (page 4)
Layout Types: Manufacturing - 33
Process flows after the Use of GT Cells
Types of LayoutTypes of LayoutGroup Technology/Cellular Layout – Example B (page 5)Group Technology/Cellular Layout – Example B (page 5)
Layout Types: Manufacturing - 34
AAAA AAAA
BBBBBBBBB BBBB
Ass
embl
y
CCCCCCCCCC CCCC
DDDDDDDDDDDDDD DDDD
Lathe
Lathe
Mill
Mill
Mill
Mill
Drill
Drill
Drill
Heat treat
Heat treat
Heat treat
Gear cut
Gear cut
Grind
Grind
Types of LayoutTypes of LayoutGroup Technology/Cellular LayoutGroup Technology/Cellular Layout
Related topic: Mixed model Assembly/manufacturing
Layout Types: Manufacturing - 35
Types of LayoutTypes of LayoutGroup Technology/Cellular LayoutGroup Technology/Cellular Layout
A family of similar partsA family of similar parts A family of related grocery itemsA family of related grocery items
Grouping parts into families
Layout Types: Manufacturing - 36
Types of LayoutTypes of LayoutGroup Technology vs. Cellular ManufacturingGroup Technology vs. Cellular Manufacturing
Potential benefits of CMPotential benefits of CM Setup time reduction Work-in-process (WIP)
reduction Material handling cost reduction Direct/indirect labor cost
reduction
Improvement in quality Improvement in material flow Improvement in machine
utilization Improvement in space
utilization Improvement in employee moral
Layout Types: Manufacturing - 37
Basic Layout TypesBasic Layout TypesProduct Volume vs. Product VarietyProduct Volume vs. Product Variety
Low Medium High
High
Medium
Low
Product Planning
Department
Fixed Materials Location Planning
Department
Process Planning
Department
Product Family Planning
Department
Product Layout
Fixed Location Layout
Group Technology Layout
Process LayoutVolu
me
Variety
Layout Types: Manufacturing - 38
Dimension Functional Cellular
Number of moves between departments Many Few
Travel distances Longer Shorter
Travel paths Variable Fixed
Job waiting times Greater Shorter
Throughput time Higher Lower
Amount of work in process Higher Lower
Supervision difficulty Higher Lower
Scheduling complexity Higher Lower
Equipment utilization Lower Higher
Types of LayoutTypes of LayoutProcess (Functional) Layout vs. Cellular LayoutProcess (Functional) Layout vs. Cellular Layout
Layout Types: Manufacturing - 39 Layout Types: Manufacturing - 39
Key:Key:SS = Saw= SawLL = Lathe= LatheHMHM = Horizontal milling = Horizontal milling
machinemachineVMVM = Vertical milling = Vertical milling
machinemachineGG = Grinder= Grinder
Paths of three Paths of three workers moving workers moving within cellwithin cell
Material Material movementmovement
InIn OutOutWorker 1Worker 1
Worker 2Worker 2
Worker 3Worker 3
Direction of part movement within cellDirection of part movement within cell
S
L
HM
VM
G
VM
L
Final inspection
Finished part
A Manufacturing Cellwith Worker Paths
Types of Layout - Types of Layout - ExampleExample
Layout Types: Manufacturing - 40
Types of Layout Types of Layout - Example- ExampleManufacturing CellManufacturing Cell
Animated Picture
Layout Types: Manufacturing - 41
Types of Layout Types of Layout - Example- ExampleManufacturing CellManufacturing Cell
An example of a hybrid layoutAn example of a hybrid layout
Layout Types: Manufacturing - 42
Types of Layout Types of Layout - Example- ExampleAutomated Manufacturing CellAutomated Manufacturing Cell
An example of a hybrid layoutAn example of a hybrid layout
Layout Types: Manufacturing - 43
Types of Layout Types of Layout - Example- ExampleFlexible Manufacturing CellFlexible Manufacturing Cell
An example of a hybrid layoutAn example of a hybrid layout
Layout Types: Manufacturing - 44
Work CellWork Cell Assembly or Production line-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility. Cells can be formed on a temporary basis.
Example: job shop with rearranged machinery and personnel to produce 30 unique control panels
Focused WorkFocused WorkCenterCenter
A permanent assembly-line-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility
Example: manufacturing of pipe brackets at a shipyard
Focused FactoryFocused Factory A permanent facility to produce a product or component in a product-oriented facility
Example: a plant to produce window mechanisms for automobiles
Types of LayoutTypes of LayoutWork Cell, Focused Work Center, and Focused FactoryWork Cell, Focused Work Center, and Focused Factory
Layout Types: Manufacturing - 45
Straight-line Flow Pattern when possible Backtracking kept to a Minimum Predictable Production Time Little In-process materials storage Open Floor plans so everyone can see what is going on Bottlenecks under control Workstations close together Minimum of material handling Easy adjustment to changing conditions
Principles of a Good LayoutPrinciples of a Good LayoutManufacturingManufacturing
Layout Types: Manufacturing - 46
New Trends in Manufacturing LayoutsNew Trends in Manufacturing Layouts
Designed for quality and flexibility Ability to quickly shift to different product models or to
different production rates Cellular layout within larger process layouts Automated material handling U-shaped production lines use to better accomplish flow control
More open work areas with fewer walls, partitions, or other obstacles
Smaller and more compact factory layouts Less space provided for storage of inventories
throughout the layout
Layout Types: Manufacturing - 47
Wrap-UpWrap-UpWorld-Class PracticesWorld-Class Practices
Strive for flexibility in layouts Multi-job training of workers Sophisticated preventive-maintenance programs Flexible machines Empowered workers trained in problem solving Layouts small and compact
Services follow the above practices plus incorporate customer needs in design
Layout Types: Manufacturing - 48
Wrap-upWrap-upAttaining Lean ProductionAttaining Lean Production
Focus on inventory reduction Build systems that help employees Reduce space requirements Develop close relationships with suppliers Educate suppliers Eliminate all but value-added activities Develop the workforce Make jobs more challenging Set sights on perfection!