Technical Note 6 Facility Layout Facility Layout and Basic Formats Process Layout Layout Planning Assembly Line balancing Service Layout

Facility Layout Defined The process by which the placement of within a facility are determined

Requirements for Facility Layout Specification of objectives Estimation Processing requirements Space requirements Space availability

Basic Production Layout Formats Process Layout Product Layout Group Technology (Cellular) Layout Fixed-Position Layout

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.

Process-Oriented Layout Floor Plan Office Table Saws © 1995 Corel Corp. Drill Presses Tool Room © 1995 Corel Corp.

Product-Oriented Layout Facility organized around product Design minimizes line imbalance Types: Fabrication line; assembly line Examples © 1984-1994 T/Maker Co.

Product-Oriented Layout Floor Plan 1 3 Operations 4 5 2 Belt Conveyor Office

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:

Work Cell Floor Plan Saws Drills Office Work Cell Tool Room

Fixed-Position Layout Design is for stationary project Workers & equipment come to site Complicating factors Limited space at site Changing material needs Examples Ship building Highway construction © 1995 Corel Corp. © 1995 Corel Corp. © 1995 Corel Corp.

Fixed Position Layout Question: What are our primary considerations for a fixed position layout?

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? Station 1 Minutes per Unit 6 Station 2 7 Station 3 3

Example of Line Balancing You’ve just been assigned the job a setting up an electric fan assembly line with the following tasks: Task Time (Mins) Description Predecessors A 2 Assemble frame None B 2 Mount switch A C 3.25 Assemble motor housing None D 1.2 Mount motor housing in frame A, C E 0.5 Attach blade D F 1.1 Assemble and attach safety grill E G 1 Attach cord B H 1.4 Test F, G

Example of Line Balancing: Step 1: Structuring the Precedence Diagram Task Predecessors Task Predecessors A None E D B A F E C None G B D A, C H F, G A B G H E C D F

Example of Line Balancing: Step 1: Precedence Diagram Question: Which process step defines the maximum rate of production? A C B D E F G H 2 3.25 1 1.2 .5 1.4 1.1

Example of Line Balancing: The Bottleneck

Example of Line Balancing: Step 2: Determine Cycle Time Question: Suppose we only have demand for 100 fans per day. What would our cycle time have to be? Answer:

Example of Line Balancing: Step 3: Determine Theoretical Minimum Number of Workstations Question: What is the theoretical minimum number of workstations for this problem? Answer:

For this example, we’ll use Example of Line Balancing: Step 4: Rules To Follow for Loading Workstations A number of simple rules have been proposed for assigning tasks to work stations. Assign Tasks With The Most Following Tasks First Assign Tasks With the Longest Task Time First For this example, we’ll use Primary: Assign tasks in order of the largest number of following tasks. Secondary (tie-breaking): Assign tasks in order of the longest operating time

Example of Line Balancing: Step 5: Make assignments A C B D E F G H 2 3.25 1.2 .5 1 1.4 Task Followers Time (Mins) A 6 2 C 4 3.25 D 3 1.2 B E 0.5 F 1 1.1 G H 1.4 23

Step 7: Evaluate the solution Example of Line Balancing: Step 6: Determine the Efficiency of the Assembly Line Step 7: Evaluate the solution

Capacity Considerations Suppose we have an assembly line: the task times are 45, 25, 18, 25, 20, 17, 20 seconds the line runs for 7 hours per day we have demand for 775 units per day Our required cycle time would be:

Options for Increasing Capacity