Layout Types: Manufacturing

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Facilities Planning - Unit 04Layout Types
Manufacturing
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Hierarchy of Facility PlanningLayout Design
Facility Location
Structural Design
Facility Planning
Facility Design
Layout Design
Handling System Design
Source for Figure Tompkins and White, Facilities
Planning, 2nd edition, Wiley
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Layout Design

• Facility layout means planning
• for the location of all machines, utilities,
  employee workstations, customer service areas,
  material storage areas, aisles, restrooms,
  lunchrooms, internal walls, offices, and computer
  rooms
• for the flow patterns of materials and people
  around, into, and within buildings

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Layout DesignPlanning for required Spaces and
Areas

• Equipment
• Work stations
• Material storage
• Rest/break areas
• Utilities
• Eating areas
• Aisles
• Offices

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Layout Design Introduction Characteristics of
the Facility Layout Decision

• Location of these various areas impacts the flow
  through the system.
• The layout can affect productivity and costs
  generated by the system.
• Layout alternatives are limited by
• the amount and type of space required for the
  various areas
• the amount and type of space available
• the operations strategy

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Basic Layout Types

• Product Layouts
• Process Layouts
• Fixed-position layouts
• Cellular/Group technology layouts

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Basic Layout TypesProduct Volume vs. Product
Variety
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Types of LayoutFixed Position Layout
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Types of LayoutFixed Position Layout

• Layout in which the product or project remains
  stationary, and workers, materials, and equipment
  are moved as needed.
• Examples
• Large construction projects (buildings, power
  plants, dams)
• Shipbuilding, production of large aircraft
• Rockets used to launch space missions

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Types of LayoutFixed Position Layout Advantages

• Material movement is reduced.
• Promotes job enlargement by allowing individuals
  or teams to perform the whole job.
• Continuity of operations and responsibility
  results from team.
• Highly flexible can accommodate changes in
  product design, product mix, and product volume.
• Independence of production centers allowing
  scheduling to achieve minimum total production
  time.

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Types of LayoutFixed Position Layout Limitations

• Increased movement of personnel and equipment.
• Equipment duplication may occur.
• Higher skill requirements for personnel.
• General supervision required.
• Cumbersome and costly positioning of material and
  machinery.
• Low equipment utilization.

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Types of LayoutProduct Type Layout
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Types of LayoutProduct Type Layout - Requirements

• Standardized product
• High production volume
• Stable production quantities
• Uniform quality of raw materials components

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Types of LayoutProduct Type Layout - Assumptions

• Volume is adequate for high equipment utilization
• Product demand is stable enough to justify high
  investment in specialized equipment
• Product is standardized or approaching a phase of
  its life cycle that justifies investment in
  specialized equipment
• Supplies of raw materials and components are
  adequate and of uniform quality ensure they will
  work with specialized equipment

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Types of LayoutProduct Type Layout - Advantages

• Since the layout corresponds to the sequence of
  operations, smooth and logical flow lines result.
• Since the work from one process is fed directly
  into the next, small in-process inventories
  result.
• Total production time per unit is short.
• Since the machines are located so as to minimize
  distances between consecutive operations,
  material handling is reduced.
• Little skill is usually required by operators at
  the production line hence, training is simple,
  short, and inexpensive.
• Simple production planning control systems are
  possible.
• Less space is occupied by work in transit and for
  temporary storage.

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Types of LayoutProduct Type Layout - Limitations

• A breakdown of one machine may lead to a complete
  stoppage of the line that follows that machine.
• Since the layout is determined by the product, a
  change in product design may require major
  alternations in the layout.
• The pace of production is determined by the
  slowest machine.
• Supervision is general, rather than specialized.
• Comparatively high investment is required, as
  identical machines (a few not fully utilized) are
  sometimes distributed along the line.

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Types of LayoutProcess Type Layout
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Types of LayoutProcess Type Layout

• Process type layouts can handle varied processing
  requirements
• The layouts feature departments or other
  functional groupings in which similar kinds of
  activities are performed
• Examples Machine shops usually have separate
  departments for milling, grinding, drilling, and
  so on
• Different products may present quite different
  processing requirements and sequences of
  operations

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Types of LayoutProcess Type Layout
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Types of LayoutProcess Type Layout - Advantages

• A high degree of flexibility exists relative to
  equipment or manpower allocation for specific
  tasks.
• Comparatively low investment in machines is
  required.
• The diversity of tasks offers a more interesting
  and satisfying occupation for the operator.

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Types of LayoutProcess Type Layout - Limitations

• Since longer flow lines usually exist, material
  handling is more expensive.
• Production planning and control systems are more
  involved.
• Total production time is usually longer.
• Comparatively large amounts of in-process
  inventory result.
• Space and capital are tied up by work in process.
• Because of the diversity of the jobs in
  specialized departments, higher grades of skill
  are required.

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Types of LayoutProcess Layout vs. Product Layout
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Types of LayoutGroup Technology/Cellular/Product
Family Layout
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Types of LayoutGroup Technology vs. Cellular
Manufacturing

• Group Technology (GT) is a management philosophy
  that attempts to group products with similar
  design or manufacturing characteristics, or both.
• Cellular Manufacturing (CM) is an application of
  GT that involves grouping machines based on the
  parts manufactured by them.
• The main objective of CM is to identify machine
  cells and part families simultaneously, and to
  allocate part families to machine cells in a way
  that minimizes the intercellular movement of
  parts.

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Original Process Layout
Types of LayoutGroup Technology/Cellular Layout
Example A (page 1)
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Original Part Routing Matrix
Types of LayoutGroup Technology/Cellular Layout
Example A (page 2)
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Reordered Part Routing Matrix
Types of LayoutGroup Technology/Cellular Layout
Example A (page 3)
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Revised Cellular Layout
Types of LayoutGroup Technology/Cellular Layout
Example A (page 4)
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Types of LayoutGroup Technology/Cellular Layout
Example B (page 1)
Unorganized Parts
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Types of LayoutGroup Technology/Cellular Layout
Example B (page 2)
Process Flows before the Use of GT Cells
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Types of LayoutGroup Technology/Cellular Layout
Example B (page 3)
Transition from Process Layout

1. Grouping parts into families that follow a common
   sequence of steps.
2. Identifying dominant flow patterns of parts
   families as a basis for location or relocation of
   processes.
3. Physically grouping machines and processes into
   cells.

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Types of LayoutGroup Technology/Cellular Layout
Example B (page 4)
Grouping parts into families
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Types of LayoutGroup Technology/Cellular Layout
Example B (page 5)
Process flows after the Use of GT Cells
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Types of LayoutGroup Technology/Cellular Layout
Related topic Mixed model Assembly/manufacturing
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Types of LayoutGroup Technology/Cellular Layout
Grouping parts into families
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Types of LayoutGroup Technology vs. Cellular
Manufacturing
Potential benefits of CM Potential benefits of CM
Setup time reduction Work-in-process (WIP) reduction Material handling cost reduction Direct/indirect labor cost reduction Improvement in quality Improvement in material flow Improvement in machine utilization Improvement in space utilization Improvement in employee moral
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Basic Layout TypesProduct Volume vs. Product
Variety
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Types of LayoutProcess (Functional) Layout vs.
Cellular Layout
Dimension Functional Cellular
Number of moves between departments Many Few
Travel distances Longer Shorter
Travel paths Variable Fixed
Job waiting times Greater Shorter
Throughput time Higher Lower
Amount of work in process Higher Lower
Supervision difficulty Higher Lower
Scheduling complexity Higher Lower
Equipment utilization Lower Higher
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Types of Layout - Example
Layout Types Manufacturing - 39
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Types of Layout - Example Manufacturing Cell
Animated Picture
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Types of Layout - Example Manufacturing Cell
An example of a hybrid layout
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Types of Layout - Example Automated Manufacturing
Cell
An example of a hybrid layout
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Types of Layout - Example Flexible Manufacturing
Cell
An example of a hybrid layout
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Types of LayoutWork Cell, Focused Work Center,
and Focused Factory
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Principles of a Good LayoutManufacturing

• Straight-line Flow Pattern when possible
• Backtracking kept to a Minimum
• Predictable Production Time
• Little In-process materials storage
• Open Floor plans so everyone can see what is
  going on
• Bottlenecks under control
• Workstations close together
• Minimum of material handling
• Easy adjustment to changing conditions

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New Trends in Manufacturing Layouts

• Designed for quality and flexibility
• Ability to quickly shift to different product
  models or to different production rates
• Cellular layout within larger process layouts
• Automated material handling
• U-shaped production lines use to better
  accomplish flow control
• More open work areas with fewer walls,
  partitions, or other obstacles
• Smaller and more compact factory layouts
• Less space provided for storage of inventories
  throughout the layout

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Wrap-UpWorld-Class Practices

• Strive for flexibility in layouts
• Multi-job training of workers
• Sophisticated preventive-maintenance programs
• Flexible machines
• Empowered workers trained in problem solving
• Layouts small and compact
• Services follow the above practices plus
  incorporate customer needs in design

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Wrap-upAttaining Lean Production

• Focus on inventory reduction
• Build systems that help employees
• Reduce space requirements
• Develop close relationships with suppliers
• Educate suppliers
• Eliminate all but value-added activities
• Develop the workforce
• Make jobs more challenging
• Set sights on perfection!