LAYOUT TYPES PRODUCT PROCESS CELLULAR (Group Technology) MIXED ADEBCFADEBCF LAYOUT BY FIXED POSITION - Ship building - Special Structures

LINKS AMONG PRODUCT, PROCESS, SCHEDULE AND LAYOUT DESIGN PRODUCT DESIGN LAYOUT DESIGN SCHEDULE DESIGN PROCESS DESIGN

PRODUCT LAYOUT 1.Smooth and logical flow lines 2.Small in process inventories. 3.Total production time/unit short. 4.Reduced material handling 5.Little operator skill, training simple 6.Simple production planning & control 7.Less space for work in transit and temporary 123n INPUTFINAL OUTPUT

A BCD F E

A B C DE F G H

P - Q CHART Product Layout Combination Layout Process Layout Q Quantity to be Made P (No. of Products or “VARIETY”

INPUT DATA & ACTIVITES 1. Flow of Materials2. Activity Relationship 3. Relationship Diagram 4. Space Reqd.5. Space Available 6. Space Relationship Diagram 7. Modifying Considerations 9. Development Layout Alternatives 10. Evaluation 8. Practical Limitation Analysis Search Selection

Operation Inspection Storage

5 Raw mtl SawLatheDrillMill Fin. goodsPackingInspection

TABLE 1 EXAMPLE PROCESSING SEQUENCES FOR THREE PRODUCTS

Table 2. FLOW RATES FOR THE PRODUCTS CONSIDERED IN TABLE 1

As such, the construction of a from-to chart is a convenient means of reducing a large volume of data into a workable from. By inspecting the data displayed in the from-to chart, the layout analyst can identify the departments having large volumes.

Fig 2 From-to chart showing number of materials handling trips per day between departments.

Normally, the from-to chart is used to analyze the flow in process layouts. The item movement that occurs over some specified period of time is totaled for all products and entered in the from-to chart. Figure 3

1 Office 2 Foreman 3 Conference room 4 Parcel post 5 Parts shipment 6 Repair and service parts 7 Service area 8 Receiving 9 Testing 10 General storage O 4 UUU 1 2 UU 1 2 U 1 2 U I 5 O U E 3 UUU U 1 4 A 1 UU E 3 A 1 E 5 O 4 U U U U U O 4 U U E U U U U U O 2

Code Reason Flow of materials Ease of supervision Common personnel Contact necessary Convenience RatingDefinition AEIOUXAEIOUX Absolutely Especially Important Important Ordinary closeness OK Unimportant Undesirable Fig.:5 Activity relationship chart

Legend A Rating E Rating I Rating O Rating U Rating X Rating

Table 3 Production Space Requirements Cont…..

Table 4 Nonproduction activity space requirements

To the 5,503 square feet of floor for production, we must add the 1,448 square feet shown in Table 4 to give an estimate of 6,951 square feet of floor space required in total.

5 (500) 8 (200) 10 (1,750) 7 (575) 9 (500) 6 (75) 4 (350) 2 (125) 3 (125) 1 (1,0) Designing the Layout

’ 65’ The Plant Layout Problem

SUMMARY Objectives in different kinds of Layout –Process, Product, Mixed Systematic Layout Planning for Process Layouts From to charts to measure material handling effort Step by Step procedure for a sample layout A precursor to Computerized Layout Planning