Communication Links among Various Design Functions

Product Design

Objectives for Facilities Layout

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Layout Design

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Operation Design

Process Design

To minimize the investment required in new equipment. To minimize the time required for production. To utilize existing space most efficiently. To provide for the convenience, safety, and comfort of the employees. To maintain a flexible arrangement. To minimize the materials handling cost. To facilitate the manufacturing process. To facilitate the organizational structure.

Layout problems develop as

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Layout problems develop gradually by

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The change in the product design. The addition or deletion of a product. Significant increase or decrease in the demand. The change in the process design. The replacement of one or more pieces of equipment. The adoption of new safety standards. Organizational changes within the company. A decision to build a new plant.

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bottlenecks crowded conditions unexplainable delays and idle time backtracking excessive temporary storage space obstacles to materials flow failure to meet schedules a high ratio of material handling time to production time

Factors affecting the flow pattern

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Factors affecting the flow pattern (continued)

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external transportation facilities number of parts in product number of operations on each part sequence of operations on each part number of subassemblies number of units to be produced necessary flow between work areas amount and shape of space available influence of processes

Types of flow patterns product vs. process type of layout location of service areas production department locations special requirements of departments material storage desired flexibility the building

Types of flow patterns

Straight line flow L-shaped flow U-shaped flow S flow Circular flow Serpentine flow Vertical flow patterns

Activity Relationship Chart

A: Absolutely necessary E: Especially important I: Important O: Ordinary importance U: Unimportant X: Undesirable

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Types of layouts
Fixed product layout
(ex) large airplanes, ships and rockets
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Product layout
(ex) assembly lines, transfer lines

Group layout Process layout

Fixed Product Layout - advantages

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Fixed Product Layout - limitations

Increased movement of personnel and equipment. Equipment duplication may occur. Higher skill requirements for personnel. General supervision required. Cumbersome and costly positioning of material and machinery. Low equipment utilization.

Material movement is reduced. Promotes job enlargement. Continuity of operations and responsibility results from team. Highly flexible (accommodating changes in product design, product mix, and production volume). Scheduling is possible to achieve minimum total production time.

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Product Layout - advantages

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Product Layout - limitations

A breakdown of one machine may lead to a complete stoppage of the line A change in product design may require major alterations in the layout. The pace of production is determined by the slowest machine. Supervision is general. Comparatively high investment is required.

Smooth and logical flow lines result. Small WIP result. Total production time per unit is short. Material handling is reduced. Training is simple, short, and inexpensive. Simple production planning and control systems are possible. Less space is occupied by work in transit and for temporary storage.

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Group Layout - advantages

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Group layout - limitations

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Increased machine utilization. Team attitude and job enlargement tend to occur. Compromise between product layout and process layout, with associated advantages. Supports the use of general-purpose equipment. Shorter travel distances and smoother flow lines than for process layout.

General supervision required. Higher skill levels required of employees than for product layout. Compromise between product layout and process layout, with associated limitations. Depends on balanced material flow through the cell. Lower machine utilization than for process layout.

Process Layout - advantages

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Process Layout - limitations

Material handling is more expensive. Production planning and control systems are more involved. Total production time is usually longer. Comparatively large amounts of WIP result. Space and capital are tied up by WIP. Higher grades of skill are required.

Better utilization of machines can result. A high degree of flexibility exists relative to equipment or manpower allocation. Comparatively low investment in machines is required. The diversity of tasks offers a more interesting and satisfying occupation for the operator. Specialized supervision is possible.

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Assignment model algorithm

1. Locate the smallest number in row 1 and subtract it from all the entries in row 1. Repeat for all rows. 2. Locate the smallest number in column 1 and subtract it from all the entries in column 1. Repeat for all columns. 3. If it is possible to make a zero cost assignment, then do it. That will be the optimal solution. If not, go to 4. 4. Determine the maximum number of zero cost assignments. 5. Choose the smallest uncovered number and do the following: a. subtract it from all other uncovered number. b. add it to the numbers where the lines cross. c. return to 3.

Computerized Layout Techniques

Construction algorithms
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PLANET CORELAP ALDEP

Improvement algorithms
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CRAFT COFAD

Measures of Distance
Euclidean distance

The single-facility rectilinear distance location problem

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( x a ) 2 + ( y b) 2
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Rectilinear distance

| x a|+| y b|

Assume that n existing facilities are located at points: (a1, b1), (a2, b2), (an, bn) Locate a new facility among n existing facilities. The goal is to find values of x and y to minimize: f(x, y) = wi (|x - ai| + |y - bi|) The weights allow different traffic rates.