Chapter 10 – Facility Layout Operations Management by R. Dan Reid & Nada R. Sanders 2nd Edition © Wiley 2005 PowerPoint Presentation by R.B. Clough - UNH

Learning Objectives Define layout planning and its importance Identify and describe different types of layouts Compare process layouts & product layouts Describe the steps involved in designing process layouts Explain the objectives of product layout design Explain the advantages of hybrid layouts Define the meaning of group technology & its importance to cellular layouts

What Is Layout Planning Layout planning is determining the best physical arrangement of resources within a facility Two broad categories of operations: Intermittent processing systems Continuous processing systems

Types of Layouts Process layouts: Product layouts: Hybrid layouts: Group similar resources together Product layouts: Designed to produce a specific product efficiently Hybrid layouts: Combine aspects of both process and product layouts Fixed-Position layouts: Product is two large to move; e.g. a building

Process Layouts General purpose & flexible resources Lower capital intensity & automation Higher labor intensity Resources have greater flexibility Processing rates are slower Material handling costs are higher Scheduling resources & work flow is more complex Space requirements are higher

Product Layouts Specialized equipment High capital intensity & wide use of automation Processing rates are faster Material handling costs are lower Less space required for inventories Less volume or design flexibility

Designing Process Layouts Step 1: Gather information: Space needed, space available, importance of proximity between various units Step 2: Develop alternative block plans: Using trial-and-error or decision support tools 2 approaches Relationship (REL) chart From-to matrix Can use both Decision support systems are heuristic methods Usually give a "good" solution Solution may not be optimal (best solution)

Designing Process Layouts (2) Step 3: Develop a detailed layout Consider exact sizes and shapes of departments and work centers including aisles and stairways Tools like drawings, 3-D models, and CAD software are often used

Process Layout Example Block layout for a sports medicine clinic A Radiology B Laboratory C Lobby & Waiting D Examining Rooms E Surgery & Recovery F Physical Therapy

Process Layout Example (2)

Process Layout Example (3)

Process Layout Example (4) Proposed Layout

Process Layout Example (5)

Office Layouts Office Layout Considerations: Almost half of US workforce works in an office environment Human interaction and communication are the primary factors in designing office layouts People who need to talk frequently should be close to each other One key layout trade-off is between proximity and privacy Open concept offices promote understanding & trust Flexible layouts with “office landscaping” help to solve the privacy issue in open office environments A few closed rooms may be needed for private discussions, such as personnel matters.

Designing Product Layouts Objectives Produce the required number of units to meet demand Use workers and equipment efficiently Balance workload among employees

Designing Product Layouts (2) Based on a precedence diagram Assign tasks to work stations Assign work stations to locations

Other Product Layout Considerations Shape of the line (S, U, O, L): Share resources, enhance communication & visibility, impact location of loading & unloading Paced versus un-paced lines Paced lines use an automatically enforced cycle time Single or mixed-model lines

Hybrid Layouts Combine elements of both product & process layouts Maintain some of the efficiencies of product layouts Maintain some of the flexibility of process layouts Examples: Group technology & manufacturing cells – used in Just-in-Time manufacturing Grocery stores

Designing Hybrid Layouts One of the most popular hybrid layouts uses Group Technology (GT) and a cellular layout GT has the advantage of bringing the efficiencies of a product layout to a process layout environment

Process Flows before the Use of GT Cells

Process Flows after the Use of GT Cells

Chapter 10 Highlights Layout planning is deciding on the best physical arrangement of resources. There are four basic types of layouts: process, product, hybrid, and fixed position. Process layouts provide flexibility to make a variety of different products. Product layouts provide greater efficiency for one product. The steps for designing process layouts are: gather space and closeness information, develop a block plan, and develop a detailed layout.

Chapter 10 Highlights (continued) The steps for designing an product layout are: identify tasks and predecessors, determine output rate, determine cycle time, computing the theoretical minimum number of work stations, assigning tasks to workstations, and computing efficiency and balance delay. Hybrids layouts combine elements from both types of layouts to increase efficiency. Hybrid layouts combine GT analysis with cellular layout concepts .