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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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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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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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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 $h#8
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n ar#y induction centre which uses product layout
%ecture theatre
Gni.ormissuing
area
Gni.ormstore
aitingarea
aitingarea
+octor
+octor
+octor
+octor
+octor
+octor
=loodtest
=loodtest
=loodtest
H@ra#
H@ra#
H@ra#
Records"ersonal
histor# andmedicaldetails
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product layout in a paper #anufacturing operation
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7 1B n inno!ati!e layout in a surgery i#pro!es its efficiency
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'hat do you thin$ 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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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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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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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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+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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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 $hen that element has been allocated
4alancing techni ues
7 37
4alancing techni"ues
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'or$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