Facility Layout

1
Part a

• Facility Layout

2
Definition (J. M. Apple)

• Arrangement of physical facilities to optimize
  the interrelationships among operating personnel,
  material flow, information flow, and the methods
  required in achieving enterprise objectives
  efficiently, economically, and safely.

3
The Overall Objective of Facility Layout

• To get the inputs (materials, supplies, etc.)
  into, through, and out of each facility in the
  shortest practicable time, at an acceptable cost.

4
Objectives of Facility Layout

• Minimize material handling costs
• Utilize space efficiently
• Utilize labor efficiently
• Eliminate bottlenecks
• Facilitate communication and interaction between
  workers, between workers and their supervisors,
  or between workers and customers
• Minimize investment in equipment

5

• Reduce manufacturing cycle time or customer
  service time
• Eliminate waste or redundant movement
• Facilitate the entry, exit, and placement of
  material, products, or people
• Incorporate safety and security measures
• Promote product and service quality
• Encourage proper maintenance activities
• Provide a visual control of operations or
  activities
• Provide flexibility to adapt to changing
  conditions
• Provide for employee convenience, safety, and
  comfort

6
Basic Types of Layouts

• Process Layout (or Lot Production)
• machines grouped by process they perform
• Product Layout (or Continuous Production)
• linear arrangement of workstations to produce a
  specific product
• Fixed Position Layout
• used in projects where the product cannot be moved

7
Hybrid Layouts

• Cellular layouts
• group machines into machining cells
• Flexible manufacturing systems
• automated machining material handling systems
• Mixed-model assembly lines
• produce variety of models on one line

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Manufacturing Process Layout
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Service Process Layout
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A Product Layout
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Comparison Of Product And Process Layouts

• PRODUCT LAYOUT PROCESS LAYOUT
• 1. Description Sequential arrangement Functional
  grouping
• of machines of machines
• 2. Type of Process Continuous, mass
  Intermittent, job shop
• production, mainly batch production,
• assembly mainly fabrication
• 3. Product Standardized Varied,
• made to stock made to order
• 4. Demand Stable Fluctuating
• 5. Volume High Low
• 6. Equipment Special purpose General purpose
• 7. Workers Limited skills Varied skills

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Comparison Of Product And Process Layouts

• PRODUCT LAYOUT PROCESS LAYOUT
• 8. Inventory Low in-process, High in-process,
• high finished goods low finished goods
• 9. Storage space Small Large
• 10. Material Fixed path Variable path
• handling (conveyor) (forklift)
• 11. Aisles Narrow Wide
• 12. Scheduling Part of balancing Dynamic
• 13. Layout decision Line balancing Machine
  location
• 14. Goal Equalize work at Minimize material
• each station handling cost
• 15. Advantage Efficiency Flexibility

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Designing Process Layouts

• Minimize material handling costs
• Block Diagramming
• minimize nonadjacent loads
• use when quantitative data is available
• Relationship Diagramming
• based on location preference between areas
• use when quantitative data is not available

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Block Diagramming

• Create load summary chart
• Calculate composite (two way) movements
• An Approach Develop trial layouts minimizing
  number of nonadjacent loads

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Block Diagramming Example
LOAD SUMMARY CHART
DEPARTMENT
DEPT.
1
2
3
4
5
1
100
50
2
200
50
3
60
40
50
4
100
60
5
50
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Initial Final Designs
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Block Diagrams
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Example 1
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Example 1 (cont.)
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Example 1 Solution
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Relationship Diagramming

• Used when quantitative data is not available
• Muthers grid displays preferences
• Denote location preferences with weighted lines

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Ranking System For Departments

• A - absolutely necessary
• E - especially important
• I - important
• O - okay
• U - unimportant
• X - undesirable

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Relationship Diagramming Example
Production
O
A
Offices
U
I
O
Stockroom
E
A
A
X
Shipping and Receiving
U
U
O
U
O
Locker Room
O
Toolroom
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Original Layout
25
Revised Layout