1. Facilities Planning - Unit 04 Layout Types: Manufacturing

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

3. 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
Layout Types: Manufacturing - 3

4. Layout Design Planning for required Spaces and Areas
Equipment
Work stations
Material storage
Rest/break areas
Utilities
Eating areas
Aisles
Offices
Layout Types: Manufacturing - 4

5. 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
Layout Types: Manufacturing - 5

6. Basic Layout Types Product Layouts Process Layouts
Fixed-position layouts
Cellular/Group technology layouts
Layout Types: Manufacturing - 6

7. Basic Layout Types Product Volume vs. Product Variety
Low Medium High
High
Medium
Low
Product Planning Department
Fixed Materials Location Planning Department
Process Planning Department
Product Family Planning Department
Product Layout
Fixed Location Layout
Group Technology Layout
Process Layout
Volume
Variety
Layout Types: Manufacturing - 7

8. Types of Layout Fixed Position Layout
Lathe
Press
Grind
Weld
Assembly
Paint
Storage
Warehouse
Layout Types: Manufacturing - 8

9. Types of Layout Fixed 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
Layout Types: Manufacturing - 9

10. Types of Layout Fixed 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.
Layout Types: Manufacturing - 10

11. Types of Layout Fixed 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.
Layout Types: Manufacturing - 11

12. Types of Layout Product Type Layout
Drill
Grind
Lathe
Storage
Warehouse
Assembly
Bend
Mill
Press
Layout Types: Manufacturing - 12

13. Types of Layout Product Type Layout - Requirements
Standardized product
High production volume
Stable production quantities
Uniform quality of raw materials & components
Layout Types: Manufacturing - 13

14. Types of Layout Product 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
Layout Types: Manufacturing - 14

15. Types of Layout Product 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.
Layout Types: Manufacturing - 15

16. Types of Layout Product 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.
Layout Types: Manufacturing - 16

17. Types of Layout Process Type Layout
Lathe
Drill
Weld
Mill
Grind
Storage
Warehouse
Paint
Assembly
Layout Types: Manufacturing - 17

18. Types of Layout Process 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
Layout Types: Manufacturing - 18

19. Types of Layout Process Type Layout
Process Layout - work travels to dedicated process centers
Milling
Assembly Test
Grinding
Drilling
Plating
Layout Types: Manufacturing - 19

20. Types of Layout Process 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.
Layout Types: Manufacturing - 20

21. Types of Layout Process 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.
Layout Types: Manufacturing - 21

22. Types of Layout Process Layout vs. Product Layout
Layout Types: Manufacturing - 22

23. Types of Layout Group Technology/Cellular/Product Family Layout
Drill
Grind
Assembly
Weld
Storage
Warehouse
Lathe
Press
Mill
Paint
Layout Types: Manufacturing - 23

24. Types of Layout Group 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.
Layout Types: Manufacturing - 24

25. Original Process Layout
Types of Layout Group Technology/Cellular Layout – Example A (page 1)
Original Process Layout C A B
Raw materials
Assembly 1 2 3 4 5 6 7 8 9 10 11 12
Layout Types: Manufacturing - 25 34

26. Original Part Routing Matrix
Types of Layout Group Technology/Cellular Layout – Example A (page 2)
Original Part Routing Matrix
Machines
Parts
A x x x x x
B x x x x
C x x x
D x x x x x
E x x x
F x x x
G x x x x
H x x x
Layout Types: Manufacturing - 26 34

27. Reordered Part Routing Matrix
Types of Layout Group Technology/Cellular Layout – Example A (page 3)
Reordered Part Routing Matrix
Machines
Parts
A x x x x x
D x x x x x
F x x x
C x x x
G x x x x
B x x x x
H x x x
E x x x
Layout Types: Manufacturing - 27 34

28. Revised Cellular Layout
Types of Layout Group Technology/Cellular Layout – Example A (page 4)
Revised Cellular Layout 3 6 9
Assembly 1 2 4 8 10 5 7 11 12
A B C
Raw materials
Cell 1
Cell 2
Cell 3
Layout Types: Manufacturing - 28 34

29. Types of Layout Group Technology/Cellular Layout – Example B (page 1)
Unorganized Parts
Layout Types: Manufacturing - 29

30. Types of Layout Group Technology/Cellular Layout – Example B (page 2)
Process Flows before the Use of GT Cells
Layout Types: Manufacturing - 30

31. Types of Layout Group Technology/Cellular Layout – Example B (page 3)
Transition from Process Layout
Grouping parts into families that follow a common sequence of steps.
Identifying dominant flow patterns of parts families as a basis for location or relocation of processes.
Physically grouping machines and processes into cells.
Layout Types: Manufacturing - 31

32. Types of Layout Group Technology/Cellular Layout – Example B (page 4)
Grouping parts into families
Layout Types: Manufacturing - 32

33. Types of Layout Group Technology/Cellular Layout – Example B (page 5)
Process flows after the Use of GT Cells
Layout Types: Manufacturing - 33

34. Types of Layout Group Technology/Cellular Layout
AAAA
BBBBBBBBB
BBBB
Assembly
CCCCCCCCCC
CCCC
DDDDDDDDDDDDDD
DDDD
Lathe
Mill
Drill
Heat
treat
Gear
cut
Grind
Related topic: Mixed model Assembly/manufacturing
Layout Types: Manufacturing - 34

35. A family of similar parts A family of related grocery items
Types of Layout Group Technology/Cellular Layout
Grouping parts into families
A family of similar parts
A family of related grocery items
Layout Types: Manufacturing - 35 34

36. Types of Layout Group Technology vs. Cellular Manufacturing
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
Layout Types: Manufacturing - 36

37. Basic Layout Types Product Volume vs. Product Variety
Low Medium High
High
Medium
Low
Product Planning Department
Fixed Materials Location Planning Department
Process Planning Department
Product Family Planning Department
Product Layout
Fixed Location Layout
Group Technology Layout
Process Layout
Volume
Variety
Layout Types: Manufacturing - 37

38. Types of Layout Process (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
Throughput time
Higher
Lower
Amount of work in process
Supervision difficulty
Scheduling complexity
Equipment utilization
Layout Types: Manufacturing - 38

39. Direction of part movement within cell
Types of Layout - Example
Key:
S = Saw
L = Lathe
HM = Horizontal milling machine
VM = Vertical milling machine
G = Grinder
Paths of three workers moving within cell
Material movement In
Out
Worker 1
Worker 2
Worker 3
Direction of part movement within cell S L HM VM G
Final inspection
Finished part
A Manufacturing Cell
with Worker Paths
Layout Types: Manufacturing - 39
Layout Types: Manufacturing - 39

40. Types of Layout - Example
Manufacturing Cell
Animated Picture
Layout Types: Manufacturing - 40 34

41. Types of Layout - Example
Manufacturing Cell
An example of a hybrid layout
Layout Types: Manufacturing - 41

42. Types of Layout - Example
Automated Manufacturing Cell
An example of a hybrid layout
Layout Types: Manufacturing - 42

43. Types of Layout - Example
Flexible Manufacturing Cell
An example of a hybrid layout
Layout Types: Manufacturing - 43

44. Types of Layout Work Cell, Focused Work Center, and Focused Factory
Assembly or Production line-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility. Cells can be formed on a temporary basis.
Example: job shop with rearranged machinery and personnel to produce 30 unique control panels
Focused Work
Center
A permanent assembly-line-oriented arrangement of machines and personnel in what is ordinarily a process-oriented facility
Example: manufacturing of pipe brackets at a shipyard
Focused Factory
A permanent facility to produce a product or component in a product-oriented facility
Example: a plant to produce window mechanisms for automobiles
Layout Types: Manufacturing - 44

45. Principles of a Good Layout Manufacturing
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
Layout Types: Manufacturing - 45

46. 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
Layout Types: Manufacturing - 46

47. Wrap-Up World-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
Layout Types: Manufacturing - 47

48. Wrap-up Attaining 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!
Layout Types: Manufacturing - 48