1. Facility Layout
Part a

2. Definition (J. M. Apple)
Arrangement of physical facilities to optimize the interrelationships among operating personnel, material flow, information flow, and the methods required in achieving enterprise objectives efficiently, economically, and safely.

3. The Overall Objective of Facility Layout
To get the inputs (materials, supplies, etc.) into, through, and out of each facility in the shortest practicable time, at an acceptable cost.

4. Objectives of Facility Layout
Minimize material handling costs
Utilize space efficiently
Utilize labor efficiently
Eliminate bottlenecks
Facilitate communication and interaction between workers, between workers and their supervisors, or between workers and customers
Minimize investment in equipment

5. Reduce manufacturing cycle time or customer service time
Eliminate waste or redundant movement
Facilitate the entry, exit, and placement of material, products, or people
Incorporate safety and security measures
Promote product and service quality
Encourage proper maintenance activities
Provide a visual control of operations or activities
Provide flexibility to adapt to changing conditions
Provide for employee convenience, safety, and comfort

6. Basic Types of Layouts Process Layout (or Lot Production)
machines grouped by process they perform
Product Layout (or Continuous Production)
linear arrangement of workstations to produce a specific product
Fixed Position Layout
used in projects where the product cannot be moved

7. Hybrid Layouts Cellular layouts Flexible manufacturing systems
group machines into machining cells
Flexible manufacturing systems
automated machining & material handling systems
Mixed-model assembly lines
produce variety of models on one line

8. Manufacturing Process LayoutD G A
Receiving and
Shipping
Assembly
Painting Department
Lathe Department
Milling
Department
Drilling Department
Grinding P

9. Service Process Layout
Women’s lingerie
Women’s dresses
Women’s sportswear
Shoes
Cosmetics and jewelry
Entry and display area
Housewares
Children’s department
Men’s department

10. A Product Layout In
Out

11. Comparison Of Product And Process Layouts
PRODUCT LAYOUT PROCESS LAYOUT
1. Description Sequential arrangement Functional grouping
of machines of machines
2. Type of Process Continuous, mass Intermittent, job shop
production, mainly batch production,
assembly mainly fabrication
3. Product Standardized Varied,
made to stock made to order
4. Demand Stable Fluctuating
5. Volume High Low
6. Equipment Special purpose General purpose
7. Workers Limited skills Varied skills

12. Comparison Of Product And Process Layouts
PRODUCT LAYOUT PROCESS LAYOUT
8. Inventory Low in-process, High in-process,
high finished goods low finished goods
9. Storage space Small Large
10. Material Fixed path Variable path
handling (conveyor) (forklift)
11. Aisles Narrow Wide
12. Scheduling Part of balancing Dynamic
13. Layout decision Line balancing Machine location
14. Goal Equalize work at Minimize material
each station handling cost
15. Advantage Efficiency Flexibility

13. Designing Process Layouts
Minimize material handling costs
Block Diagramming
minimize nonadjacent loads
use when quantitative data is available
Relationship Diagramming
based on location preference between areas
use when quantitative data is not available

14. Block Diagramming Create load summary chart
Calculate composite (two way) movements
An Approach: Develop trial layouts minimizing number of nonadjacent loads

15. Block Diagramming Example
LOAD SUMMARY CHART
DEPARTMENT
DEPT. 1 2 3 4 5 1
100 50 2
200 50 3 60 40 50 4
100 60 5 50

16. Initial & Final Designs

17. Block Diagrams

18. Example 1

19. Example 1 (cont.)

20. Example 1: Solution

21. Relationship Diagramming
Used when quantitative data is not available
Muther’s grid displays preferences
Denote location preferences with weighted lines

22. Ranking System For Departments
A - absolutely necessary
E - especially important
I - important
O - okay
U - unimportant
X - undesirable

23. Relationship Diagramming Example
Production O A
Offices U I O
Stockroom E A A X
Shipping and Receiving U U U O O
Locker Room O
Toolroom

24. Original Layout

25. Revised Layout