Slide 0 of 96 Manufacturing Facility Layout

Slide 1 of 96 Basic Layout Forms Process Product Cellular Fixed position Hybrid

Slide 2 of 96 Sistem produksi Intermitten Lay out by process Saw Mill Grind Lathe Paint Drill Assembly Warehouse Stores

Slide 3 of 96 Tata Letak Proses (Manufacturing Process Layout) L L L L L L L L L L M M M M D D D D D D D D G G G G G G P P AAA Receiving and Shipping Assembly Painting Department Lathe Department Milling Department Drilling Department Grinding Department

Slide 4 of 96 Sistem produksi Continous Lay out by product Saw Grind Weld Lathe Mill Grind Mill Drill Lathe Drill Paint Drill Stores Assembly Warehouse

Slide 5 of 96 Process (Job Shop) Layouts Equipment that perform similar processes are grouped together Used when the operations system must handle a wide variety of products in relatively small volumes (i.e., flexibility is necessary)

Slide 6 of 96 Characteristics of Process Layouts General-purpose equipment is used Changeover is rapid Material flow is intermittent Material handling equipment is flexible Operators are highly skilled... more

Slide 7 of 96 Characteristics of Process Layouts Technical supervision is required Planning, scheduling and controlling functions are challenging Production time is relatively long In-process inventory is relatively high

Slide 8 of 96 Product (Assembly Line) Layouts Operations are arranged in the sequence required to make the product Used when the operations system must handle a narrow variety of products in relatively high volumes Operations and personnel are dedicated to producing one or a small number of products

Slide 9 of 96 Characteristics of Product Layouts Special-purpose equipment are used Changeover is expensive and lengthy Material flow approaches continuous Material handling equipment is fixed Operators need not be as skilled... more

Slide 10 of 96 Characteristics of Product Layouts Little direct supervision is required Planning, scheduling and controlling functions are relatively straight-forward Production time for a unit is relatively short In-process inventory is relatively low

Slide 11 of 96 Product Layout- Advantages/Disadvantages Advantages: ùLow cost variable cost per unit ùLower material handling costs ùreduction in work in- process inventories ùeasier training and supervision Disadvantages: ÷High volume required because of large initial investment ÷Lack of flexibility in handling variety of products or production rates

Slide 12 of 96 Tata Letak Proses (Manufacturing Process Layout) L L L L L L L L L L M M M M D D D D D D D D G G G G G G P P AAA Receiving and Shipping Assembly Painting Department Lathe Department Milling Department Drilling Department Grinding Department

Slide 13 of 96 Part Routing Matrix Reordered To Highlight Cells MACHINES PARTS A x x xxx Dxx x xx Fx xx Cxxx Gxxxx Bxxx Hxxx Ex x x

Slide 14 of 96 Cellular Layout Solution

Slide 15 of 96 Designing and Analyzing a Product Layout Line Balancing

Slide 16 of 96 Designing and Analyzing a Product Layout Characteristics Inputs Design Procedure How Good Is The Layout?

Slide 17 of 96 Line Balancing Problem Work stations are arranged so that the output of one is an input to the next, i.e., a series connection Layout design involves assigning one or more of the tasks required to make a product to work stations... more

Slide 18 of 96 Line Balancing Problem The objective is to assign tasks to minimize the workers’ idle time, therefore idle time costs, and meet the required production rate for the line In a perfectly balanced line, all workers would complete their assigned tasks at the same time (assuming they start their work simultaneously) This would result in no idle time... more

Slide 19 of 96 Inputs The production rate required from the product layout or the cycle time. –The cycle time is the reciprocal of the production rate and visa versa All of the tasks required to make the product –It is assumed that these tasks can not be divided further... more

Slide 20 of 96 Inputs The estimated time to do each task The precedence relationships between the tasks –These relationships are determined by the technical constraints imposed by the product –These relationships are displayed as a network known as a precedence diagram

Slide 21 of 96 Design Procedure 1. If not provided, find the cycle time for the line. Remember the cycle time is the reciprocal of the production rate. Make sure the cycle time is expressed in the same time units as the estimated task times. 2. Select the line-balancing heuristic that may be used to help with the assignments. (Two heuristics are described at the end of this procedure.)... more

Slide 22 of 96 Design Procedure 3. Open a new work station with the full cycle time remaining. 4. Determine which tasks are feasible, i.e., can be assigned to this work station at this time. For a task to be feasible, two conditions must be met: –All tasks that precede that task must have already been assigned –The estimated task time must be less than or equal to the remaining cycle time for that work station.

Slide 23 of 96 Line-Balancing Heuristics Heuristic methods, based on simple rules, have been used to develop very good, not optimal, solutions to line balancing problems.

Slide 24 of 96 How Good Is the Design? Utilization is one way of objectively determining how near perfectly balanced an assignment scheme is. Utilization is the percentage of time that a production line is working. Utilization is calculated as: or

Slide 25 of 96 Station 1 Min/ Unit 6 Station 2 7 Station 3 3 Why is Balancing the Line Important? What’s Going to Happen?

Slide 26 of 96 Example 1: The ALB Problem You’ve just been assigned the job a setting up an electric fan assembly line with the following tasks:

Slide 27 of 96 Example 1: The ALB Problem The Precedence Diagram A C B DEF G H Which process step defines the maximum rate of production?

Slide 28 of 96 Example 1: The ALB Problem The Bottleneck

Slide 29 of 96 Example 1: The ALB Problem We want to assemble 100 fans per day What do these numbers this represent?

Slide 30 of 96 Example 1: The ALB Problem We want to assemble 100 fans per day Why should we always round up?

Slide 31 of 96 Example 1: The ALB Problem Selected Task Selection Rules Primary: Assign tasks in order the the largest number of following tasks. Secondary (tie-breaking): Assign tasks in order of the longest operating time

Slide 32 of 96 Example 1: The ALB Problem Selected Task Selection Rules Precedence Diagram A C B DEF G H

A C B DEF G H Station 1Station 2 Station 3 TaskFollowersTime (Min) A62 C43.25 D31.2 B2 1 E20.5 F11 G11 H01.4 Slide 33 of 96

A C B DEF G H Station 1Station 2 Station 3 TaskFollowersTime (Min) A62 C43.25 D31.2 B2 1 E20.5 F11 G11 H01.4 A (4.2-2=2.2) Slide 34 of 96

A C B DEF G H Station 1Station 2 Station 3 TaskFollowersTime (Min) A62 C43.25 D31.2 B2 1 E20.5 F11 G11 H01.4 A (4.2-2=2.2) B (2.2-1=1.2) Slide 35 of 96

A C B DEF G H Station 1Station 2 Station 3 TaskFollowersTime (Min) A62 C43.25 D31.2 B2 1 E20.5 F11 G11 H01.4 A (4.2-2=2.2) B (2.2-1=1.2) G (1.2-1=.2) Idle=.2 Slide 36 of 96

A C B DEF G H Station 1Station 2 Station 3 TaskFollowersTime (Min) A62 C43.25 D31.2 B2 1 E20.5 F11 G11 H01.4 A (4.2-2=2.2) B (2.2-1=1.2) G (1.2-1=.2) Idle=.2 C ( )=.95 Idle =.95 Slide 37 of 96

A C B DEF G H Station 1Station 2 Station 3 TaskFollowersTime (Min) A62 C43.25 D31.2 B2 1 E20.5 F11 G11 H01.4 A (4.2-2=2.2) B (2.2-1=1.2) G (1.2-1=.2) Idle=.2 C ( )=.95 Idle =.95 D ( )=3 Slide 38 of 96

A C B DEF G H Station 1Station 2 Station 3 TaskFollowersTime (Min) A62 C43.25 D31.2 B2 1 E20.5 F11 G11 H01.4 A (4.2-2=2.2) B (2.2-1=1.2) G (1.2-1=.2) Idle=.2 C ( )=.95 Idle =.95 D ( )=3 E (3-.5)=2.5 Slide 39 of 96

A C B DEF G H Station 1Station 2 Station 3 TaskFollowersTime (Min) A62 C43.25 D31.2 B2 1 E20.5 F11 G11 H01.4 A (4.2-2=2.2) B (2.2-1=1.2) G (1.2-1=.2) Idle=.2 C ( )=.95 Idle =.95 D ( )=3 E (3-.5)=2.5 F (2.5-1)=1.5 Slide 40 of 96

A C B DEF G H Station 1Station 2 Station 3 TaskFollowersTime (Min) A62 C43.25 D31.2 B2 1 E20.5 F11 G11 H01.4 A (4.2-2=2.2) B (2.2-1=1.2) G (1.2-1=.2) C ( )=.95 D ( )=3 E (3-.5)=2.5 F (2.5-1)=1.5 H ( )=.1 Idle=.2Idle=.95 Idle=.1 Slide 41 of 96

Slide 42 of 96 Example 1: The ALB Problem Which station is the bottleneck? What is the effective cycle time?