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8/8/2019 Lecture-6 8 Facilities Layout
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Facilities LayoutFacilities LayoutDr. KDS Pathania
Dr. KDS Pathania
LectureLecture -- 66
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Facility layoutFacility layout
MinimizematerialMinimizematerial--handlinghandlingcostscosts
Utilize spaceefficientlyUtilize spaceefficiently
UtilizelaborefficientlyUtilizelaborefficiently
EliminatebottlenecksEliminatebottlenecks FacilitatecommunicationFacilitatecommunication
andinteractionandinteraction
ReducemanufacturingcycleReducemanufacturingcycletimetime
ReducecustomerserviceReducecustomerservicetimetime
Eliminate wasted orEliminate wasted orredundantmovementredundantmovement
IncreasecapacityIncreasecapacity
Facilitate entry,exit,andFacilitate entry,exit,andplacement ofmaterial,placement ofmaterial,products,and peopleproducts,and people
Incorporate safetyandIncorporate safetyand
securitymeasuressecuritymeasures Promote productand servicePromote productand service
qualityquality
Encourage properEncourage propermaintenanceactivitiesmaintenanceactivities
Provideavisualcontrol ofProvideavisualcontrol ofactivitiesactivities
Provideflexibilityto adapttoProvideflexibilityto adapttochangingconditionschangingconditions
Arrangement ofareas withinafacilityto:
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Basic layoutsBasic layouts
Process layoutsProcess layouts
group similaractivities togetheraccordingtogroup similaractivities togetheraccordingtoprocess orfunctionthey performprocess orfunctionthey perform
ProductlayoutsProductlayouts arrangeactivities inlineaccordingto sequence ofarrangeactivities inlineaccordingto sequence of
operations fora particularproduct orserviceoperations fora particularproduct orservice
FixedFixed--positionlayoutspositionlayouts
areusedforprojects in which productcannotbeareusedforprojects in which productcannotbemovedmoved
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Process layout in servicesProcess layout in services
Womensessentials
Womensdresses
Womenssportswear
Shoes
Cosmeticsand jewelry
Entry anddisplay area
Housewares
Childrensdepartment
Mensdepartment
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Manufacturing Process LayoutManufacturing Process Layout
L
L
L
L
L
L
L
L
L
LM
M
M
M
D
D
D
D
D
D
D
D
G
G
G
G
G
G
A A AReceiving andShipping Assembly
Painting Department
Lathe DepartmentMilling
Department Drilling Department
GrindingDepartment
P
P
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AProduct LayoutAProduct Layout
InIn
OutOut
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Description
Type ofprocess
Product
Demand Volume Equipment
Description
Type ofprocess
Product
Demand Volume Equipment
Sequential
arrangement ofactivities
Continuous,mass
production,mainly
assembly
Standardized,madetostock
Stable
High
Special purpose
Process
Comparison ofProductComparison ofProduct
and Process Layoutsand Process Layouts
Functionalgrouping of
activities Intermittent, job shop,
batch production,
mainlyfabrication
Varied,madeto order
Fluctuating
Low General purpose
Product
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Workers
Inventory
Storage space
Materialhandling
Aisles
Scheduling
Layoutdecision
Goal
Advantage
Workers
Inventory
Storage space
Materialhandling
Aisles
Scheduling
Layoutdecision
Goal
Advantage
Limited skills
Low in-process,high
finishedgoods Small
Fixed path (conveyor)
Narrow
Part ofbalancing
Linebalancing
Equalize workateach
station
Efficiency
Process
Comparison ofProductComparison ofProduct
and Process Layoutsand Process Layouts
Varied skills
Highin-process,low
finishedgoods Large
Variable path (forklift)
Wide
Dynamic
Machinelocation
Minimizematerial
handlingcost
Flexibility
Product
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FixedFixed--Position LayoutsPosition Layouts
Typical ofprojectsTypical ofprojects
Equipment, workers,Equipment, workers,
materials, othermaterials, other
resources broughttoresources broughttothe sitethe site
Highly skilledlaborHighly skilledlabor
Oftenlow fixedOftenlow fixed
TypicallyhighvariableTypicallyhighvariable
costscosts
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Designing Process LayoutsDesigning Process Layouts
Goal: minimizematerialhandlingcostsGoal: minimizematerialhandlingcosts
BlockDiagrammingBlockDiagramming
minimizenonadjacentloadsminimizenonadjacentloads
use when quantitativedatais availableuse when quantitativedatais available
Relationship DiagrammingRelationship Diagramming
based onlocation preferencebetweenareasbased onlocation preferencebetweenareas
use when quantitativedatais notavailableuse when quantitativedatais notavailable
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Block DiagrammingBlock Diagramming
UnitloadUnitload
quantityin whichquantityin which
materialis normallymaterialis normally
movedmoved
NonadjacentloadNonadjacentload
distancefartherthanthedistancefartherthanthe
nextblocknextblock
StepsSteps
createload summarycreateload summary
chartchart
calculatecomposite (twocalculatecomposite (twoway)movementsway)movements
develop triallayoutsdevelop triallayouts
minimizingnumberofminimizingnumberof
nonadjacentloadsnonadjacentloads
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Block Diagramming: ExampleBlock Diagramming: Example
DepartmentDepartment 11 22 33 44 55
Load Summary ChartLoad Summary Chart
FROM/TOFROM/TO DEPARTMENTDEPARTMENT
11 100100 5050
22 200200 5050
33 6060 4040 5050
44 100100 606055 5050
1 2 3
4 5
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Block Diagramming:Block Diagramming:Example (cont.)Example (cont.)
2 3 200loads
2 4 150loads
1 3 110loads1 2 100loads
4 5 60loads
3 5 50loads
25 5
0loads3 4 40loads
1 4 0loads
1 5 0loads
1 2 3
4 5
100 200
150
50
50
60
40
110
Grid 1
NonadjacentLoads:
110+40=150
1 2
3
4
5
100
200
150
50
50
60
40
110
Grid 2
NonadjacentLoads:
0
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Block Diagramming:Block Diagramming:Example (cont.)Example (cont.)
12
3
4
53
2
5
1 4
(a) Initial block diagram(a) Initial block diagram (b) Final block diagram(b) Final block diagram
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Relationship DiagrammingRelationship Diagramming
SchematicdiagramthatSchematicdiagramthat
uses weightedlines touses weightedlines to
denotelocationdenotelocation
preferencepreference Muthers gridMuthers grid
formatfordisplayingformatfordisplaying
managerpreferences formanagerpreferences for
departmentlocationsdepartmentlocations
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RelationshipRelationship
DiagrammingDiagramming
ProductionProduction
OfficesOffices
StockroomStockroom
Shipping andShipping andreceivingreceiving
Locker roomLocker room
ToolroomToolroom
AA AA
AA
OO
OO
OOOO OO
UU
UU
UU
UU
EEXX
II
A Absolutelynecessary
E Especiallyimportant
I ImportantO Okay
U Unimportant
X Undesirable
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Relationship Diagrams:Relationship Diagrams:Example (cont.)Example (cont.)
(a) Relationship diagram of original layout(a) Relationship diagram of original layout
Key:Key: AAEE
II
OO
UU
XX
OfficesOffices
StockroomStockroom
LockerLockerroomroom
ToolroomToolroom
ShippingShippingandand
receivingreceiving
ProductionProduction
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(b) Relationship diagram of revised layout(b) Relationship diagram of revised layout
OfficesOffices
StockroomStockroom
LockerLockerroomroom
ToolroomToolroom
ShippingShippingandand
receivingreceiving
ProductionProduction Key:Key: AAEE
II
OO
UU
XX
Relationship Diagrams:Relationship Diagrams:Example (cont.)Example (cont.)
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Computerized layout solutionsComputerized layout solutions
CRAFTCRAFT ComputerizedRelative Allocation ofFacilities TechniqueComputerizedRelative Allocation ofFacilities Technique
CORELAPCORELAP
ComputerizedRelationship Layout PlanningComputerizedRelationship Layout Planning PROMODELandEXTENDPROMODELandEXTEND
visualfeedbackvisualfeedback
allow userto quicklytestavariety ofscenariosallow userto quicklytestavariety ofscenarios
ThreeThree--Dmodelingand CADDmodelingand CAD integratedlayoutanalysisintegratedlayoutanalysis
availableinVisFactoryand similarsoftwareavailableinVisFactoryand similarsoftware
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Designing Service LayoutsDesigning Service Layouts
MustbebothattractiveandfunctionalMustbebothattractiveandfunctional
TypesTypes
Freeflow layoutsFreeflow layouts
encouragebrowsing,increaseimpulse purchasing,areflexibleandencouragebrowsing,increaseimpulse purchasing,areflexibleandvisuallyappealingvisuallyappealing
GridlayoutsGridlayouts
encouragecustomerfamiliarity,arelow cost,easyto cleanandencouragecustomerfamiliarity,arelow cost,easyto cleanand
secure,andgoodforrepeatcustomerssecure,andgoodforrepeatcustomers
Loop andSpinelayoutsLoop andSpinelayouts
bothincreasecustomersightlines andexposureto products, whilebothincreasecustomersightlines andexposureto products, while
encouraging customerto circulatethroughtheentire storeencouraging customerto circulatethroughtheentire store
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Types of Store LayoutsTypes of Store Layouts
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Designing Product LayoutsDesigning Product Layouts
ObjectiveObjective BalancetheassemblylineBalancetheassemblyline
LinebalancingLinebalancing
tries to equalizetheamount ofworkateach workstationtries to equalizetheamount ofworkateach workstation PrecedencerequirementsPrecedencerequirements
physicalrestrictions onthe orderin which operations arephysicalrestrictions onthe orderin which operations areperformedperformed
CycletimeCycletime maximumamount oftimea productis allowedto spendatmaximumamount oftimea productis allowedto spendat
each workstationeach workstation
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Cycle Time ExampleCycle Time Example
Cd =production time available
desired units of output
Cd=
(8 hours x 60 minutes / hour)
(120 units)
Cd
= =4 minutes480
120
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Flow Time vs Cycle TimeFlow Time vs Cycle Time
Cycletime=maxtime spentatany stationCycletime=maxtime spentatany station
Flow time=timeto completeall stationsFlow time=timeto completeall stations
1 2 3
4 minutes4 minutes 4 minutes4 minutes 4 minutes4 minutes
Flow time = 4 + 4 + 4 = 12 minutesFlow time = 4 + 4 + 4 = 12 minutes
Cycle time = max (4, 4, 4) = 4 minutesCycle time = max (4, 4, 4) = 4 minutes
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Efficiency of Line
ii
ii= 1= 1ttii
nCnCaaEE==
ii
ii= 1= 1ttii
CCddNN==
EfficiencyEfficiencyMinimum numberMinimum number
of workstationsof workstations
wherewhere
ttii = completion time for element= completion time for element ii
jj = number of work elements= number of work elements
nn = actual number of workstations= actual number of workstations
CCaa
= actual cycle time= actual cycle time
CCdd
= desired cycle time= desired cycle time
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Line Balancing ProcedureLine Balancing Procedure
1. Draw andlabela precedencediagram
2. Calculate desiredcycletimerequiredfortheline
3. Calculate theoreticalminimumnumberofworkstations
4. Group elements into workstations,recognizingcycletimeand precedenceconstraints
5. Calculate efficiency oftheline
6. Determineifthetheoreticalminimumnumberof
workstations oranacceptableefficiencylevelhasbeenreached. Ifnot,go backto step 4.
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Line Balancing: ExampleLine Balancing: Example
WORK ELEMENTWORK ELEMENT PRECEDENCEPRECEDENCE TIME (MIN)TIME (MIN)
AA Press out sheet of fruitPress out sheet of fruit 0.10.1
BB Cut into stripsCut into strips AA 0.20.2
CC Outline fun shapesOutline fun shapes AA 0.40.4DD Roll up and packageRoll up and package B, CB, C 0.30.3
0.10.1
0.20.2
0.40.4
0.30.3D
B
C
A
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Line Balancing: Example (cont.)Line Balancing: Example (cont.)
WORK ELEMENTWORK ELEMENT PRECEDENCEPRECEDENCE TIME (MIN)TIME (MIN)
AA Press out sheet of fruitPress out sheet of fruit 0.10.1
BB Cut into stripsCut into strips AA 0.20.2
CC Outline fun shapesOutline fun shapes AA 0.40.4DD Roll up and packageRoll up and package B, CB, C 0.30.3
Cd
=
=
=0.4 minute
40 hours x 60 minutes / hour
6,000 units
2400
6000
N= = = 2.5 3 workstations1.0
0.4
0.1 + 0.2 + 0.3 + 0.4
0.4
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Line Balancing: Example (cont.)Line Balancing: Example (cont.)
CCdd
= 0.4= 0.4
NN= 2.5= 2.5
REMAINING REMAININGWORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, C
B 0.1 C, D
2 C 0.0 D3 D 0.1 none
0.10.1
0.20.2
0.40.4
0.30.3D
B
C
A
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A, B C D
Work
station 1
Work
station 2
Work
station 3
0.3
minute
0.4
minute
0.3
minute
CCdd
= 0.4= 0.4
NN= 2.5= 2.5
E= = = 0.833 = 83.3%0.1 + 0.2 + 0.3 + 0.4
3(0.4)
1.0
1.2
Line Balancing: Example (cont.)Line Balancing: Example (cont.)
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Computerized Line BalancingComputerized Line Balancing
Useheuristics to assigntasks to workstationsUseheuristics to assigntasks to workstations
Longest operationtimeLongest operationtime
Shortest operationtimeShortest operationtime
MostnumberoffollowingtasksMostnumberoffollowingtasks
LeastnumberoffollowingtasksLeastnumberoffollowingtasks
Ranked positional weightRanked positional weight
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CellularLayouts
1.1. Identifyfamilies ofparts with similarIdentifyfamilies ofparts with similar
flow pathsflow paths
2.2. Group machines into cells based onGroup machines into cells based on
partfamiliespartfamilies
3.3. Arrangecells so materialmovementArrangecells so materialmovement
is minimizedis minimized
4.4. Locatelarge sharedmachines atLocatelarge sharedmachines atpoint ofusepoint ofuse
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Parts FamiliesParts Families
A family ofA family of
similar partssimilar parts
A family of relatedA family of related
grocery itemsgrocery items
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Original Process LayoutOriginal Process Layout
CA B Raw materials
Assembly
1
2
3
4
5
6 7
8
9
10
11
12
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Part Routing MatrixPart Routing Matrix
Machines
Parts 1 2 3 4 5 6 7 8 9 10 11 12
A x x x x x
B x x x x
C x x x
D x x x x x
E x x x
F x x xG x x x x
H x x x
Figure 5.8Figure 5.8
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Revised CellularLayoutRevised CellularLayout
3
6
9
Assembly
12
4
8 10
5
7
11
12
A B C
Raw materials
Cell 1 Cell 2 Cell 3
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Reordered Routing MatrixReordered Routing Matrix
Machines
Parts 1 2 4 8 10 3 6 9 5 7 11 12
A x x x x x
D x x x x x
F x x x
C x x x
G x x x x
B x x x xH x x x
E x x x
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Key:Key:
SS = Saw= Saw
LL =Lathe=Lathe
HMHM = Horizontal milling machine= Horizontal milling machine
VMVM = Vertical milling machine= Vertical milling machine
GG = Grinder= Grinder
Paths of threePaths of threeworkers movingworkers moving
within cellwithin cell
MaterialMaterial
movementmovement
InIn OutOut
Worker 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
Finalinspection
Finishedpart
A Manufacturing Cell with
WorkerPathsSource: J.T. Black, Cellular Manufacturing
Systems Reduce Setup Time, Make Small Lot
Production Economical.IndustrialEngineering(November1983).
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Automated Manufacturing CellAutomated Manufacturing Cell
Source: J. T. Black, Cellular
Manufacturing Systems Reduce Setup
Time, Make Small Lot
Production Economical. Industrial
Engineering(November1983)
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Advantages and DisadvantagesAdvantages and DisadvantagesofCellularLayoutsofCellularLayouts AdvantagesAdvantages
ReducedmaterialReducedmaterial
handlingandtransittimehandlingandtransittime
Reduced setup timeReduced setup time
Reduced workReduced work--inin--
process inventoryprocess inventory
Betteruse ofhumanBetteruse ofhuman
resourcesresources
Easierto controlEasierto control
Easierto automateEasierto automate
DisadvantagesDisadvantages
Inadequate partfamiliesInadequate partfamilies
PoorlybalancedcellsPoorlybalancedcells
ExpandedtrainingandExpandedtrainingandschedulingscheduling
ofworkersofworkers
IncreasedcapitalIncreasedcapital
investmentinvestment
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Flexible Manufacturing SystemsFlexible Manufacturing Systems(FMS)(FMS) FMSconsists ofnumerous programmableFMSconsists ofnumerous programmable
machinetools connectedbyanautomatedmachinetools connectedbyanautomatedmaterialhandling systemandcontrolledbyamaterialhandling systemandcontrolledbya
commoncomputernetworkcommoncomputernetwork FMScombines flexibility withefficiencyFMScombines flexibility withefficiency
FMSlayouts differbased onFMSlayouts differbased on
variety ofparts thatthe systemcan processvariety ofparts thatthe systemcan process
size of parts processedsize of parts processed
average processingtimerequiredforpartaverage processingtimerequiredforpartcompletioncompletion
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Full-Blown FMS
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Mixed Model Assembly LinesMixed Model Assembly Lines
Producemultiplemodels inany orderon oneProducemultiplemodels inany orderon one
assemblylineassemblyline
Issues inmixedmodellinesIssues inmixedmodellines
LinebalancingLinebalancing
UU--shapedlineshapedline
Flexible workforceFlexible workforce
Model sequencingModel sequencing
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Balancing UBalancing U--Shaped LinesShaped Lines
A B C
D E
Precedence diagram:Precedence diagram:
Cycle time = 12 minCycle time = 12 min
A,B C,D E
(a) Balanced for a straight line(a) Balanced for a straight line
9 min9 min 12 min12 min 3 min3 min
Efficiency = = = .6666 = 66.7 %Efficiency = = = .6666 = 66.7 %24243636
24243(12)3(12)
12 min12 min 12 min12 min
C,D
A,B
E
(b) Balanced for a U(b) Balanced for a U--shaped lineshaped line
Efficiency = = = 100 %Efficiency = = = 100 %2424
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2424
2(12)2(12)