Facility Layout

Chapter 10 pages 343-355, 366-367

MGMT 326

Foundations

of Operatio

nsIntroductio

n

Strategy

ManagingProjects

QualityAssuran

ce

Facilities

Products &

Processes

ProductDesign

ProcessDesign

ManagingQuality

Statistical

ProcessControl

Just-in-Time & Lean Systems

FacilityLayout

Capacity

and Locatio

n

Planning& Control

Presentation Outline

Importance of layout planning Types of layouts

Comparing process and product layouts

Designing process layouts Designing cellular layouts Office layouts

What Is Layout Planning?

Layout planning is determining the best physical arrangement of resources within a facility

Why is layout planning important?

Eliminates unnecessary costs for space and materials handling

Reduces work-in-process inventory Produces goods and services faster Reduces distances that workers must

travel in the workplace Improves communication and morale Increases retail sales Improves brand image

Types of Layouts Process layouts: Group similar resources together Product layouts: Designed to produce a specific

product, or a small number of products efficiently Hybrid layouts: Combine aspects of both process

and product layouts Examples: cellular layout, grocery store

Fixed-Position layouts: Product is too large to move Examples: building construction, shipyard Resources must be brought to where they are

needed

Process and Product Layouts

Process Layouts Used in project and batch

manufacturing (intermittent processes) Also used in department stores, offices,

hospitals, and universities Able to make or sell a variety of

products Use general purpose resources Less automation than in product layouts

Process Layouts (2)

Material handling costs per unit are higher than in product layouts

Scheduling production is more complex than in product layouts

Product Layouts

Used in assembly lines and continuous manufacturing (repetitive processes)

A cafeteria line is a product layout In manufacturing, product layouts are

used to produce one product, or a small group of products, efficiently

Uses special purpose resources More automation than in process

layouts

Product Layouts (2)

Material handling costs per unit are lower than in process layouts

Scheduling production is simpler than in process layouts

Designing Process Layouts Step 1: Gather information:

Space needed, space available, importance of proximity between various units

Step 2: Develop alternative block plans: Using trial-and-error or decision support tools 2 approaches

Relationship (REL) chart From-to matrix

Can use both Decision support systems are heuristic methods

Usually give a "good" solution Solution may not be optimal (best solution)

Designing Process Layouts (2)

Step 3: Develop a detailed layout Consider exact sizes and shapes of

departments and work centers including aisles and stairways

Tools like drawings, 3-D models, and computer-assisted design (CAD) software are often used

Process Layout Example

Block layout for a sports medicine clinic

ARadiology

BLaboratory

CLobby & Waiting

DExamining

Rooms

ESurgery & Recovery

FPhysical Therapy

Process Layout Example (2)

Process Layout Example (3)

Proposed Layout

Process Layout Example (4)

ARadiology

BExamining

Rooms

CLobby & Waiting

DSurgery &Recovery

ELaboratory

FPhysical Therapy

Process Layout Example (5)

Cellular Layouts

Used to make parts in Just-in-Time Manufacturing

Based on group technology Group technology (GT): A method of

organizing parts into families with similar manufacturing requirements

A manufacturing cell is created for each part family

An Example of Group Technology

© Wiley 2007

Process Flows before the Use of GT Cells

© Wiley 2007

Process Flows after the Use of GT Cells

Office Layouts Almost half the U. S. work force works in

an office Human interaction and communication

are the primary considerations in office layouts

People who need to interact frequently should be close to each other

One key layout tradeoff is between closeness and privacy

Office Layouts (2)

Open concept offices promote understanding and trust.

A few closed rooms are needed for private discussions, such as personnel matters.

Moveable walls provide flexibility to change the layout when needed.

Office Layout Example3D Systems

Hi-tech company – provides equipment and materials for rapid product design and manufacturing

Rock Hill headquarters handles product design, sales, training, and administration

Open office plan Conference room Areas for informal meetings Product showroom for customers Cyber café and fitness center for employees