1 Slides used in class may be different from slides in student pack Technical Note 6 Facility Layout  Facility Layout and Basic Formats  Process Layout Planning  Assembly Line balancing

2 Slides used in class may be different from slides in student pack Facility Layout Defined within a facility are determined The process by which the placement of

3 Slides used in class may be different from slides in student pack Requirements for Facility Layout  Specification of objectives  Estimation  Processing requirements  Space requirements  Space availability

4 Slides used in class may be different from slides in student pack Basic Production Layout Formats  Process Layout  Product Layout  Group Technology (Cellular) Layout  Fixed-Position Layout

5 Slides used in class may be different from slides in student pack Process-Oriented Layout  Design places departments with large flows of material or people together  Dept. areas have similar processes –  Used with process-focused processes  Examples – © 1995 Corel Corp.

6 Slides used in class may be different from slides in student pack Process-Oriented Layout Floor Plan Office Tool Room Drill Presses Table Saws © 1995 Corel Corp.

7 Slides used in class may be different from slides in student pack Product-Oriented Layout  Facility organized around product  Design minimizes line imbalance –  Types: Fabrication line; assembly line  Examples – © T/Maker Co.

8 Slides used in class may be different from slides in student pack Product-Oriented Layout Floor Plan Office Belt Conveyor Operations

9 Slides used in class may be different from slides in student pack Cellular Layout - Group Technology (Work Cells)  Special case of process-oriented layout  Consists of different machines brought together to make a product  Group Technology Benefits: – – – –

10 Slides used in class may be different from slides in student pack Work Cell Floor Plan Office Tool Room Work Cell SawsDrills

11 Slides used in class may be different from slides in student pack Flows in a functional layout/job shop Drilling D D DD Grinding G G GG GG Milling MM MM MM Assembly A A AA Lathing Receiving and shipping L LL LL LL L Source: Mikell P. Groover. Automation, Production Systems, and Computer-Aided Manufacturing. Englewood Cliffs, NJ: Prentice-Hall, 1980, pp

12 Slides used in class may be different from slides in student pack Group Technology/Cellular Layout Cell 3 LM G G Cell 1 Cell 2 Assembly area A A L M D L L M Shipping D Receiving G Source: Mikell P. Groover. Automation, Production Systems, and Computer-Aided Manufacturing. Englewood Cliffs, NJ: Prentice-Hall, 1980, pp

13 Slides used in class may be different from slides in student pack Fixed-Position Layout  Design is for stationary project  Workers & equipment come to site  Complicating factors –Limited space at site –Changing material needs  Examples – © 1995 Corel Corp.

14 Slides used in class may be different from slides in student pack Fixed Position Layout Question: What are our primary considerations for a fixed position layout?

15 Slides used in class may be different from slides in student pack Retail Service Layout  Goal--maximize net profit per square foot of floor space.  Servicescapes – – –

16 Slides used in class may be different from slides in student pack Special Service Cases  Warehouse layout - ASRS - Cross-Docking  Grocery layout - shelf placements, store placements - grouping associated products  Office layouts - offices without walls

17 Slides used in class may be different from slides in student pack Process Layout: Interdepartmental Flow  Given – The flow (number of moves) to and from all departments – The cost of moving from one department to another – The existing or planned physical layout of the plant  Determine – The “best” locations for each department, where best means interdepartmental transportation, flow, costs, etc.

18 Slides used in class may be different from slides in student pack Process Layout: CRAFT Approach  It is a heuristic program; it uses a simple rule of thumb in making evaluations: –  It does not guarantee an optimal solution.  CRAFT assumes the existence of variable path material handling equipment such as forklift trucks.

19 Slides used in class may be different from slides in student pack Process Layout: Systematic Layout Planning  Numerical flow of items between departments – –  Systematic Layout Planning – –

20 Slides used in class may be different from slides in student pack Example of Systematic Layout Planning: Reasons for Closeness Code Reason Type of customer Ease of supervision Common personnel Contact necessary Share same price Psychology

21 Slides used in class may be different from slides in student pack Example of Systematic Layout Planning: Importance of Closeness Value A E I O U X Closeness Line code Numerical weights Absolutely necessary Especially important Important Ordinary closeness OK Unimportant Undesirable

22 Slides used in class may be different from slides in student pack Example of Systematic Layout Planning: Relating Reasons and Importance From 1. Credit department 2. Toy department 3. Wine department 4. Camera department 5. Candy department 6 I -- U 4 E U U 1 I 1,6 A -- U 1 X 1 X To Area (sq. ft.) Letter Number Closeness rating Reason for rating

23 Slides used in class may be different from slides in student pack Example of Systematic Layout Planning: Initial Relationship Diagram X X E A I

24 Slides used in class may be different from slides in student pack Example of Systematic Layout Planning: Initial and Final Layouts Taking into Account Space Needs Initial Layout Ignoring space and building constraints ft 20 ft Final Layout Adjusted by square footage and building size

25 Slides used in class may be different from slides in student pack Relationship Chart Example Ordinary closeness: President (1) & costing (2) Absolutely necessary: President (1) & secretary (4) I = Important; U = Unimportant

26 Slides used in class may be different from slides in student pack Based on the relationships, where should the departments be placed in the following building?

27 Slides used in class may be different from slides in student pack Assembly-Line Balancing  Assigning all tasks to a series of workstations so that each workstation has no more work than what can be done in the cycle time and so that the idle time across all work stations is minimized.  Includes precedence relationships (order in which tasks must be done)

28 Slides used in class may be different from slides in student pack Station 1 Minutes per Unit 6 Station 2 7 Station 3 3 Assembly Lines Balancing Concepts Question: Suppose you load work into the three work stations below such that each will take the corresponding number of minutes as shown. What is the cycle time of this line?