1. Facility Layout
Chapter 6A

2. Learning Objectives
Understand how production processes are typically organized and the trade-off between efficiency and flexibility offered by each design.
Gain experience with the basic tools used to design workcenters, assembly lines, and manufacturing cells.
Recognize typical retail and office layout designs.

3. Layout Decisions
Facility layout: the process of determining placement of departments, workgroups within departments, workstations, machines, and stock-holding points within a facility
This process requires the following inputs:
Specification of the objectives used to evaluate the design
Estimates of product or service demand
Processing requirements
Space requirements for the elements
Space availability within the facility
LO 1 3

4. Product–Process Matrix: Framework Describing Layout Strategies
LO 4

5. Project Layout
LO 3

6. Project Layout Continued
The product remains in a fixed location
A high degree of task ordering is common
A project layout may be developed by arranging materials according, to their assembly priority
LO 3

7. Workcenter
LO 3

8. Workcenter Continued
Most common approach to developing this type of layout is to arrange workcenters in a way that optimizes the movement of material
Optimal placement often means placing workcenters with large interdepartmental traffic adjacent to each other
Sometimes is referred to as a department and is focused on a particular type of operation
LO 3

9. Manufacturing Cell
LO 3

10. Manufacturing Cell Continued
Group parts into families that follow a common sequence of steps
Identify dominant flow patterns for each part family
Machines and the associated processes are physically regrouped into cells
LO 3

11. Flexible Line Layouts

12. Assembly Line Balancing
Specify the sequential relationships among tasks
Determine the required workstation cycle time
Determine the theoretical minimum number of workstations
Select a primary and secondary assignment rule
Assign tasks
Evaluate the efficiency of the balance
Rebalance if needed
LO 2

13. Assembly Line Balancing Formula
LO 2

14. Example: Assembly Steps and Times for Wagon built Production of 500 Wagons and 8 hr/work shift (2-15 min. breaks and 30 mins. For lunch included)
LO 2

15. Example: Precedence Diagram
LO 2

16. Example: C and Nt Primary rule: Largest following tasks
Secondary rule: Longest task time
LO 2

17. Example: Assignment
LO 2

18. Example: Efficiency
LO 2

19. Service Businesses
A service business is the management of organizations whose primary business requires interaction with the customer to produce the service
Generally classified according to who the customer is:
Financial services
Health care
A contrast to manufacturing 5

20. Retail Service Layout
Goal--maximize net profit per square foot of floor space
Servicescapes
Ambient conditions
Background characteristics, such as noise
Spatial layout and functionality
Planning the circulation path of customers and grouping merchandise
Signs, symbols, and artifacts
Parts of the service that have social significance
LO 3 37

21. Alternative Store Layouts
LO 3

22. Office Layout More open offices Low divider walls
Size and orientation of desks indicates importance of people behind them
LO 3

23. Degree of Patience
No Way!
No Way!
BALK
RENEG 7

24. Any Questions?