Facility Layout

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Facility Layout 

• Facility Layout decisions translate the broader
  decisions about a firms strategy such as
  competitive priorities, process, and capacity
  into actual physical arrangements of people,
  equipment, and space.

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Emphasis On flexibility and change

• Determine         Placement of
  departments         Workgroups within
  departments         Workstations        
  Machines         Stock-holding points Factory
  smooth work flow Service traffic pattern 

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Inputs to layout decisions

• specification of the objectives
• estimates of product or service demand
• processing requirements
• space requirements
• space availability existing facility
• building configuration new facility 

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Basic Production Layout Formats

• Process Layout - Job shop/functional layout
• Similar equipment or functions are grouped
  together
• Tools Interdepartmental Flow Systematic
  Layout Planning Distance/Load Basis
• Product Layout - Assembly Line
• Equipment is arranged according to the steps in
  which the product is made Tools Line
  balancing Group Technology (cellular) Fixed-po
  sition layout

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Retail Service Layout

• Stores, banks, restaurants Goal maximize net
  profit per square foot of floor space

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Servicescapes

• 1.        Ambient conditions 2.        Spatial
  layout and functionality3.        Signs,
  symbols, and artifacts         

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Office Layout

• Trends
• more open offices
• removed fixed walls to foster communication and
  teamwork
• size and orientation of desks
• often designed and laid out to convey a desired
  image  

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Marks of a Good Layout

• Manufacturing Back-Office Operations1.       
  Straight line flow patterns2.       
  Backtracking minimized3.        Production time
  predictable4.        Little inter-stage storage
  of materials5.        Open plant floors so
  everyone can see what is happening
• 6.        Bottleneck operations under
  control7.        Workstations close
  together8.        Orderly handling and storage
  of materials9.        No unnecessary re-handling
  of material10.     Easily adjustable to changing
  conditions 

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Face-to-face services

• 1.  easily understood service flow
  pattern2.  adequate waiting facilities3.  easy
  communication with customers4.  easily
  maintained customer surveillance5.  clear exit
  and entry points with adequate checkout
  capabilities6.   departments and processes
  arranged so that customers only see what you
  want them to see7.   balance between waiting
  areas and service areas8.   minimum walking and
  material movement9.   lack of clutter
• 10.    high sales volume per square foot of
  facility 

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Conditions that drive layout decisions

• -          reduce unnecessary activities-       
     prevent damage to inventory-          enhance
  communication-          prevent
  rework-          provide privacy-         
  provide for employee safety-          provide
  for security of resources-          enhance
  labor skills and functional excellence-      
      enhance the quality of work life-         
  provide for customer involvement  

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• The goal of layout planning is to allow workers
  and equipment to operate most effectively
• Economic activity center anything in your
  facility that consumes space

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Questions to ask

• What centers to include?
• How much space and capacity does each center
  need?
• How should each centers space be configured?
• Where should each center be located?

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• Relative location placement relative to other
  centers based on
• Travel time
• Material handling costs
• Communication needs
• Absolute location particular space it will
  occupy

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Designing a Process Layout

• Gather information
• Develop a block plan
• Design a detailed layout

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Gather information

• Space requirements for each center
• Available space
• Closeness factors
• Trip matrix
• REL (relationship chart)
• What centers need fixed locations

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Develop a block plan

• Trial and error for acceptable plan
• LOAD-DISTANCE method

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Process Layout Example
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Detailed representation

• Exact size and shape of each center
• Arrangement of elements

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Designing a Product layout

• Arranges work stations in sequence
• LINE BALANCING assignment of work to stations
• Goal Obtain workstations with well-balanced
  workloads
• Work element smallest unit of work that can be
  performed independently

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Procedure

• Develop a precedence diagram
• Determine the desired output rate
• Determine cycle time and related measures
• Find an appropriate solution

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• Cycle time 1/r where r is the desired output
  rate
• Maximum time allowed for work on a unit at each
  station
• Theoretical Minimum Number of Workstations
• TM ?t / c
• Idle Time n c - ?t
• where n number of stations
• Efficiency () ?t / nc (100)
• Balance Delay () 100 - Efficiency

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Finding a Solution

• Begin with station k 1
• Make a list of candidates to assign to station k
• Pick a candidate
• Longest work-element rule
• Largest number of followers
• Calculate cumulative time for all tasks assigned
  to station k
• If some work elements are still unassigned, but
  none are candidates for station k, create a new
  station k1
• Continue until all work elements are assigned

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