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

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

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

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

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

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

8. Product-Oriented Layout Floor Plan1 3
Operations 4 5 2
Belt Conveyor
Office

9. 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. Work Cell Floor Plan
Saws
Drills
Office
Work Cell
Tool Room

11. 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
© Corel Corp.
© Corel Corp.
© 1995 Corel Corp.

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

13. 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

14. 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

15. 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

16. 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

17. Example of Line Balancing: The Bottleneck

18. 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:

19. 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:

20. 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

21. 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

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

23. 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:

24. Options for Increasing Capacity