Lesson 9 - Layout and Flow

8/12/2019 Lesson 9 - Layout and Flow

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Slack, Chambers and Johnston, Operations Management , 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 20107 1

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Chapter 7

Layout

and flow

Pearson Education Ltd. Rob Judges


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!rocess designSu""l# net$ork design

%a#outand &lo$

!rocesstechnolog#

!eo"le, 'obsand

organi(ation

!roduct)ser*icedesign

+esign

!lanning andcontrol

"erations

strateg#

-m"ro*ement

Layout and flow

%a#outand .lo$


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Slack, Chambers and Johnston, Operations Management , 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 20107 /

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o introduce the t$o conce"ts o. "rocess t#"e and la#outt#"e and the relationshi" bet$een them

o describe the basic la#out t#"es in terms o. the nature o.the .lo$ o. trans.ormed resources through the "rocess

o stress that most real la#outs are h#brids o. the "uret#"es

o identi.# some o. the sim"le a""roaches that can be usedto determine the e act nature o. a la#out

Key Teaching Ob ecti!es


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-n Cha"ter 7 4 %a#out and .lo$4 Slack et al identi.# the.ollo$ing ke# 5uestions

hat is la#out8

hat are the basic la#out t#"es used in o"erations8

hat t#"e o. la#out should an o"eration choose8

9o$ should each basic la#out t#"e be designed in detail8

Key operations "uestions


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Slack, Chambers and Johnston, Operations Management , 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 20107 :

7 :

he relati*e "ositioningo. trans.orming resources;i e deciding $here to "ut all the .acilities,machines, e5ui"ment and sta.. in the o"erations clothes

%uggage andgi.ts

Con.ectioner #,

ne$s"a"er,maga(ines

andstationer#

=ooksand

*ideos&oot$e

ar

!er.umeand

'e$eller#

Ele*ators

Entrance

E n t r a n c e


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3 !roduct la#out!roduct la#out in*ol*es locating the trans.orming resources entirel# .or the

con*enience o. the trans.ormed resourcesEach "roduct, "iece o. in.ormation or customer .ollo$s a "rearrangedroute in $hich the se5uence o. acti*ities that are re5uired matches these5uence in $hich the "rocesses ha*e been located

he trans.ormed resources ?.lo$> as in a ?line> through the "rocess his is$h# this t#"e o. la#out is sometimes called .lo$ or line layout&lo$ is "redictable and there.ore relati*el# eas# to control E am"les o."roduct la#out include

utomobile assembly almost all variants of the same model re!uire the samese!uence of "rocesses

&oan application processing all applications re!uire the same se!uence ofclerical and decision@making acti*ities

Self-service cafeteria generally the se!uence of customer re!uirements(starter# main course, dessert, drink< is common to all customers, but la#out alsohel"s control customer .lo$

The four basic layout types


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Slack, Chambers and Johnston, Operations Management , 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 20107 1:

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Product flow in Cadbury&s

&lo$ o. chocolate inCadbur#>s .actor#

&lo$ o. customers inCadbur# orld

=oth Cadbur#>s chocolate .actor# and its ?Cadbur# orld>*isitor attraction use ?"roduct> la#out =ut $hat $ill be di..erentabout the la#outs and $h#8


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n ar#y induction centre which uses product layout

%ecture theatre

Gni.ormissuing

area

Gni.ormstore

aitingarea

aitingarea

+octor

+octor

+octor

+octor

+octor

+octor

=loodtest

=loodtest

=loodtest

H@ra#

H@ra#

H@ra#

Records"ersonal

histor# andmedicaldetails


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7 17

product layout in a paper #anufacturing operation


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Slack, Chambers and Johnston, Operations Management , 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 20107 1B

7 1B n inno!ati!e layout in a surgery i#pro!es its efficiency


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Slack, Chambers and Johnston, Operations Management , 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 20107 1D

7 1D

'hat do you thin$ are the ad!antages and disad!antages of thisarrange#ent when co#pared with the con!entional layout of onesurgeon re#aining in one operating theatre(

he .irst "oint to make here is that, essentiall#, the la#out has not changedas such =oth a con*entional o"erating theatre and the arrangementdescribed in the short case are ?.i ed "osition> la#outs hat has changed isthat, t$o "atients are mo*ed in and out o. their o"erating theatres ;the .i ed"ositions< in order .or "re"aration $ork that does not in*ol*e the surgeon tobe carried out $hilst the surgeon is o"erating on the other "atient his hasthe ad*antage o. utili(ing $hat "resumabl# is the scarce resource ;thesurgeon< e*en though t$o o"erating theatres are no$ needed o somee tent, it is mo*ing to$ards the "rinci"les o. .lo$ "rocesses because,

although the "atient does not mo*e as such, the# do mo*e relati*e to thesurgeon

)actory flow helps surgery producti!ity

/i0 d l t1 t t # l 0 ith ll f b i


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7 20 /i0ed layout1 restaurant co#ple0 with all four basiclayout types

&i ed@"osition la#outser*ice restaurant

Cell la#out bu..et

%inela#outca.eteria

Cool room

&ree(er Iegetable "re"rill

!re"aration

, * e n

&unctional la#out kitchen

ain coursebu..et

S t a r t e r

b u

. . e t

+ e s s e r t

b u

. . e t

Ser*ice line


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&unctional la#out

+isad*antages

Ad*antages

9igh "roduct and mi .le ibilit#

Relati*el# robust in the case o.disru"tions

Eas# to su"er*ise

%o$ utili(ation

Can ha*e *er# high -!

Com"le .lo$

d!antages and disad!antages of functional layout

7 2:


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7 2:

Cell la#out

+isad*antages

Ad*antages

Can gi*e good com"romise

&ast through"ut

rou" $ork can result in goodmoti*ation

Can be costl# to rearrangee isting la#out

Can need more "lant

d!antages and disad!antages of cell layout

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!roduct la#out

+isad*antages

Ad*antages

%o$ unit costs .or high *olume

""ortunities .or s"eciali(ation

o. e5ui"ment

Can ha*e lo$ mi .le ibilit#

Not *er# robust in the case o.disru"tions

ork can be *er# re"etiti*e

d!antages and disad!antages of product layout

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Ser*ice

.unctional t#"es

ass ser*ices

Ser*ice sho"s

anu.acturing

.unctional t#"es

Continuous "rocesses

ass "rocesses

=atch "rocesses

=asic la#out

t#"es

&i ed@"osition la#out

&unctional la#out

Cell la#out

!roduct la#out

The relationship between process types and layout types

Jobbing "rocesses

!ro.essional ser*ices

!ro'ect "rocesses

7 2B 4asic layout types ha!e different fi0ed and !ariable costs


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Slack, Chambers and Johnston, Operations Management , 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 20107 2B

7 2B 4asic layout types ha!e different fi0ed and !ariable coststhat see# to deter#ine which one to use

Iolume

C o s

t s

Gse "roductGsecellGse

.unctionalGse .i ed@"osition

&i ed@"osition

&unctional Cell

!roduct

7 2D 4ut uncertainty about e0act fi0ed and !ariable costs


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Slack, Chambers and Johnston, Operations Management , 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 20107 2D

7 2D 4ut uncertainty about e0act fi0ed and !ariable costs#eans the decision can rarely be #ade on cost alone

Iolume

C o s

t s &i ed@"osition

&unctional

Cell

!roduct

Gse .i ed@"osition

Gse .unctional

Gse .i ed@"osition or .unctional

(

Gse .unctional or cell

(

Gse .unctional or cell or "roduct

(

Gse "roduct

7 /0

l d d h


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Slack, Chambers and Johnston, Operations Management , 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 20107 /0

7 /0

+etailed design techni"ues

&i ed "osition 4 resource location anal#sis

&unctional la#out 4 .lo$ charts and relationshi" charts

Cell la#out 4 "roduct .lo$ anal#sis

!roduct la#out 4 assembl# line balancing techni5ues

nce the basic la#out t#"e has been decided, the ne t

ste" is to decide the detailed design o. the la#out

he ob'ecti*e o. the detailed design o. .i ed@"osition la#outs is to achie*e ala#out .or the o"eration $hich allo$s all the trans.orming resources toma imi(e their contribution to the trans.ormation "rocess b# allo$ing them

to "ro*ide an e..ecti*e ?ser*ice> to the trans.ormed sources

7 /1

il d d i f f i l l


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he detailed design o. .unctional la#outs is com"le , as is .lo$ in this t#"eo. la#outChie. among the .actors $hich lead to this com"le it# is the *er# largenumber o. di..erent o"tions&or ) centres there are .actorial ) ()* different ways of arranging thecentres

his co#binatorial co#ple0ity of functional layouts #a$es o"timalsolutions di..icult to achie*e in "ractice

ost .unctional la#outs are designed b# a combination o. intuition,common sense and s#stematic trial and error

5nfor#ation re"uired before detailed design of functional layouts he area re5uired b# each $ork centreF

he constraints on the sha"e o. the area allocated to each $ork centreF he degree and direction o. .lo$ bet$een each $ork centre ;.or e am"le,number o. 'ourne#s, number o. loads or cost o. .lo$ "er distance tra*elled


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A = C + E

A 17 - /0 10= 1/ 20 20

C 10 - 70+ /0 - - /0E 10 10 10 10

A = C + E

A /0 - 60 20= /0 - /0C - B0+ 30

E

;b o. "arts

7 30 +etailed design of product layout


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Rather than ?$here to "lace $hat>, "roduct la#out isconcerned more $ith ?$hat to "lace $here>

%ocations are .re5uentl# decided u"on and then $ork tasksare allocated to each location&or e am"le, it ma# ha*e been decided that .our stations areneeded to make com"uter cases

he decision then is $hich o. the tasks that go into makingthe cases should be allocated to each station

he main "roduct la#out decisions are as .ollo$s hat c#cle time is needed8

9o$ man# stages are needed ;number o. $orkstations


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Cycle ti#e is the ti#e between co#pleted products% "ieces o.in.ormation or customers emerging .rom the "rocess-t is calculated b# considering the likel# demand .or the "roducts orser*ices o*er a "eriod and the amount o. "roduction time a*ailablein that "eriod

'or$ed E0a#pleSu""ose the regional [email protected] o"eration o. a large bank is designing an

o"eration $hich $ill "rocess its mortgage a""lications he number o.a""lications to be "rocessed is 160 "er $eek and the time a*ailable to"rocess the a""lications is 30 hours "er $eek

So the bank>s la#out must be ca"able o. "rocessing a com"leted a""licationonce e*er# 1: minutes

The cycle ti#e of product layouts

C#cle time .or the la#out L ime A*ailable L 30 L 1 L 1: minutes

No o be"rocessed

160 3

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:u#ber of stages ; wor$stations ; :o of wor$ers


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he ne t decision concerns the number o. stages in the la#out andde"ends on the c#cle time re5uired and the total 5uantit# o. $orkin*ol*ed ; total wor$ content in "roducing the "roduct or ser*iceThe larger the total wor$ content and the smaller the re5uiredc#cle time, the more stages $ill be necessar#

'or$ed E0a#pleSu""ose the bank in the "re*ious e am"le calculated that the a*erage total

$ork content o. "rocessing a mortgage a""lication is 60 minutes henumber o. stages needed to "roduce a "rocessed a""lication e*er# 1:minutes can be calculated as .ollo$s

:u#ber of stages ; wor$stations ; :o. of wor$ers

Number o. stages L total $ork content L 60 minutes L 3 stages

re5uired c#cle time 1: minutes

7 3/

4alancing wor$ ti#e allocation


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Slack, Chambers and Johnston, Operations Management , 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 20107 3/

ne o. the most im"ortant design decisions in "roduct la#out is thato. line balancing.5n the mortgage@"rocessing e am"le $e ha*e assumed that the 1:minutes o. $ork content are allocated e5uall# to the .our stations

his is nearl# al$a#s im"ossible to achie*e in "ractice and someimbalance in the $ork allocation results

'or$ed E0a#ple-n &igure o*erlea. the $ork allocations in a .our@stage line are illustrated he

total amount o. time in*ested in "roducing each "roduct or ser*ice is .ourtimes the c#cle time because, .or e*er# unit "roduced, all .our stages ha*ebeen $orking .or the c#cle time hen the $ork is e5uall# allocatedbet$een the stages, the total time in*ested in each "roduct or ser*ice

"roduced is 3 2 : L 10 minutes 9o$e*er, $hen $ork is une5uall#allocated, as illustrated, the time in*ested is / 0 3 L 12 minutes, i e 2 0minutes o. time, 16 67 "er

cent o. the total, is $asted

4alancing wor$-ti#e allocation

7 33 4alancing loss is that proportion of the ti#e in!ested ini h d !i hi h i d d i! l


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processing the product or ser!ice which is not used producti!ely

An ideal ?balance> $here $ork is allocated e5uall# bet$een the stages

% o a

d

0

0 :

1

1 :

2

2 :

/

1 2 / 3Stage

C#cle time L 2 : mins ork allocated to stage

7 3: 4alancing loss is that proportion of the ti#e in!ested in processingh d !i hi h i d d i! l 6C i d


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the product or ser!ice which is not used producti!ely 6Continued

=ut i. $ork is not e5uall# allocated, the c#cle time $ill increase and?balancing losses> $ill occur

ork allocated to stage

% o a

d

0

0 :

1

1 :

2

2 :

/

1 2 / 3Stage

C#cle time L / 0 mins/ :

-dle time

C a l c u l a t i n g b a l

a n c i n g l o s s

- d l e t i m e

e * e r # c # c l e

L ; / 0 4 2 / < O

; / 0 4 2 : < O ; /

0 4 2 2 into the time remaining at the stage Choose the element $ith the most ?.ollo$ers> that is the highest number o.

elements $hich can onl# be allocated $hen that element has been allocated

4alancing techni ues

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4alancing techni"ues


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'or$ed E0a#pleQarlstad Qakes ;QQ< is a manu.acturer o. s"ecialit# cakes, $hich hasrecentl# obtained a contract to su""l# a ma'or su"ermarket chain $ith a

s"ecialit# cake in the sha"e o. a s"ace rocket -t has been decided that the*olumes re5uired b# the su"ermarket $arrant a s"ecial "roduction line to"er.orm the .inishing, decorating and "acking o. the cake his line $ouldha*e to carr# out the elements sho$n in .igure o*erlea., $hich also sho$sthe "recedence diagram .or the total 'ob he initial order .rom the

su"ermarket is .or :,000 cakes a $eek and the number o. hours $orked b#the .actor# is 30 "er $eek &rom this

4alancing techni ues

he re5uired c#cle time L 30 hrs 60 mins L 0 3B minutes

:,000

he re5uired number o. stages L 1 6B min ;the total $ork content< L / : stages

0 3B min ;the re5uired c#cle time

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Lesson 9 - Layout and Flow