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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