Facility Layout - Meeting 8-9

Course - 1 02/03/2017
Facility Layout Design TIN 314 (Course 8)
Flow, space, and activity relationship

Three important considerations in determining the requirement
of a facility:
Flow
FLOW PATTERN ANALYSIS
Space
Course 8 Activity Relationships
Facility Layout Design TIN 314 (Course 8) Facility Layout Design TIN 314 (Course 8)
Production Planning Department Production Planning Department

Production Departments: Collections of workstations
Depending on product volume-variety, production department
can be classified as:
Product (Production Line) Departments
Process Departments
Fixed Material Location Departments
Product Family Departments
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Production Planning Department
Cellular Manufacturing System

Manufacturing Cell
Organizations using modern manufacturing approaches are
combining production, support, administrative, and service
planning departments to create integrated departments e.g.
a manufacturing cell
Manufacturing Cells group machines, employees, materials,
tooling, and material handling and storage equipment to
produce families of parts.
The most important benefits are achieved when the cells are
designed, controlled, and operated using JIT, TQM, and TEI
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An Assembly Cellular A FLOW PROCESS

A flow process considers three factors:
Subject of flow
The resources that bring about flow
Communications that coordinate the resources
A Logistic System Segments of flow

Flow of materials Flow of materials Flow of products
into a facility within a facility From a facility
Flow into a manufacturing facility
Flow withina manufacturing facility
Flow from a manufacturing facility
The material management, material flow, and physical distribution

system form a logistic system
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The Material Flow System FLOW PATTERN

Flow Within Workstation
motion studies and ergonomics considerations
Flow should be simultaneous, coordinated, symmetrical, natural,
rhythmical, and habitual
Flow Within Departments
Is dependent on the type of department (product vs. process
dept.)
Flow Between Departments
Used to evaluate overall flow within facility
Flow Within Departments: Flow Within Departments:

Product Layout Process Layout
Little flow between workstations
Flow occurs between workstations and aisles
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Flow pattern : Flow Within Departments Flow pattern : Flow Within Departments
Flow within departments with material handling considerations Flow within departments with material handling considerations
Line flow patterns Spine, tree and loop flow patterns
Flow Between Departments Flow Between Departments

Flow typically is a combination of the basic horizontal flow patterns Flow within a facility considering the locations of entrance and exit
shown below.
An important consideration in combining the flow patterns is the
location of the entrance (receiving department) and exit (shipping
department).
Similar to
Simplest. Separate L flow straight. It is
Straight receiving/shipping not as long.
crews
Very popular.
Combine receiving Circular Terminate flow.
U flow Near point of
/shipping. Simple flow
to administer origin
Serpentine
When line is too
long S flow
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Flow Between Departments Example

Flow within a facility -pattern categories
Vertical Flow Pattern FLOW PLANNING

The effective flow within a facility depends on effective flow between
departments. Such flow depends on effective flow within
departments, which depends on effective flow within workstations.
Flow between buildings exists Ground level ingress Ground level ingress (entry)
and the connection between (entry) and egress (exit) and egress (exit) occur on the
buildings is elevated are required same side of the building
Travel between floors Some bucket and belt Backtracking occurs due
occurs on the same side conveyors and escalators to the return to the top
of the building result in inclined flow floor
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Signs of a good general flow pattern

A flow starts at receiving and terminates at shipping.
Straight and short lines of flow
Minimum backtracking
Material is moved directly to point of use
Minimum WIP
Flow pattern is easily expandable, new processes can easily
be merged in
Principles of effective flow

Principles of effective flow
Maximize directed (uninterrupted) flow paths
A directed flow path is an uninterrupted flow path progressing Minimize backtracking: Backtracking increases the length of the
directly from origin to destination flow path
The congestion and undesirable intersections may occur when flow
paths are interrupted.
Uninterrupted flow paths
Interrupted flow paths
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Principles of effective flow Principles of effective flow

Effects of backtracking in a unidirectional loop flow system
Minimize flow
Deliver materials, information, or people directly to the point
of ultimate use
Plan for flow between two consecutive points of use to take
place in a few moments as possible
Combine flows and operations
Maximize directed flow path
Minimize the cost of the flow
Minimize manual handling (automate or mechanize the flow)
Minimize trips of empty carriers
MEASURING FLOW Quantitative Flow Measurement:

Quantitative flow measurement
Large volumes of materials, information, a number of people
From-to Chart
moving between departments 1. List all departments down the row and across the column following
In terms of amount moved or distance travelled the overall flow pattern.
From-To-Chart 2. Establish a measure of flow for the facility that accurately indicates
Qualitative flow measurement equivalent flow volumes.
Very little actual movement of materials, information, and people If the items moved are equivalent with respect to ease of movement, the number
flowing between departments of trips may be recorded in the from-to chart.
Significant communication and organizational interrelation If the items moved vary in size, weight, value, risk of damage, shape, and so on,
between departments then equivalent items may be established so that the quantities recorded in the
from-to chart represent the proper relationships among the volumes of
In terms of the level of relationship between units (departments)
movement.
in the organizations
Relationship Chart 3. Based on the flow paths for the items to be moved and the
established measure of flow, record the flow volumes in the from-to
Usually both measurements are used chart.
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Material Flow: From-To-Chart: Example with equivalent items

From-To-Chart
From-To-Chart
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Relationship Chart Relationship Chart

Relationship Chart measures the flows qualitatively using Due to the great variety and multiplicity of relationships
the closeness relationships values involved, it is advisable to construct separate relationship
charts for each major relationship being measured:
material flow
personnel flow
information flow
organizational, control, environmental, and process
relationships, etc.
Qualitative Flow Measurement: Activity Relationship Chart

Activity Relationship Chart Relationship Chart may include the closeness values in conjunction
with reasons for the value
1. List all departments on the relationship chart.
2. Conduct interviews of surveys with persons from each department
listed on the relationship chart and with the management
responsible for all departments.
3. Define the criteria for assigning closeness relationships and itemize
and record the criteria as the reasons for relationship values on the
relationship chart.
4. Establish the relationship value and the reason for the value for all
pairs of departments.
5. Allow everyone having input to the development of the relationship
chart to have an opportunity to evaluate and discuss changes in the
chart.
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Facility Layout Design TIN 314 (Course 9)
SPACE REQUIREMENTS
The most difficult determination in facilities planning
The design year: 5-10 years
Approach: From the ground up
SPACE REQUIREMENT: In manufacturing and office environments, space
requirements should be determined first for individual
Workstation and Production Department workstations; next, departments, etc.
Modern manufacturing approaches can reduce space
requirements.
Course 9
SPACE REQUIREMENTS WORKSTATION REQUIREMENTS

Equipment space
Workstation Specification (space for equipment, materials, 1. The equipment
2. Machine travel
and personnel) 3. Machine maintenance
Department Specification 4. Plant services
Aisle Arrangement Equipment space requirements are available from machinery data
Visual Management and Space Requirement sheets (provided by the supplier). If this data is not available, the
following information must be obtained for each machine:
- Machine manufacturer and type - Maximum travel to the left
- Machine model and serial number - Maximum travel to the right
- Location of machine safety stops - Static depth at maximum point
- Floor loading requirement - Maximum travel towards the operator
- Static height at maximum point - Maximum travel away from the operator
- Maximum vertical travel - Maintenance requirements and areas
- Static width at maximum point - Plant service requirements and areas
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WORKSTATION REQUIREMENTS Workstation

Area requirements for a machine:
Total width = (static width) + (max. travel to left) + (max. travel to right)
Total depth = (static depth) + (max. travel toward operator) +
(max. travel away from operator)
Area (machine + machine travel) = (total width) * (total depth)
Materials space
1. Receiving and storing materials
2. In-process materials
3. Storing and shipping materials
4. Storing and shipping waste and scrap
5. Tools, fixture, jigs, dies, and maintenance materials
Personnel area
1. The operator (motion & ergonomic study)
2. Material handling
3. Operator ingress and egress (Operator way in and way out)
Department Specification Tables for Aisle Allowance

Once the space requirements for the workstations have been
determined, the department space requirements should be Table 1. Aisle Allowance Estimates Table 2. Recommended Aisle Widths
defined. Aisle Allowance for Various Types of Flow
If the Largest Load is (Percentage of Net
Departmental area: Area Required) Type of Flow Aisle Width
2 (ft)
1. Sum of areas of workstations Less than 6 ft
Between 6 and 12 ft
2
5 10
10 20 Tractors 12
2 3-ton Forklift 11
2. Equipment maintenance Between 12 and 18 ft
Greater than 18 ft
2
20 30
30 - 40 2-ton Forklift 10
Tooling, dies, plant services
1-ton Forklift 9
3.
These may be shared!
Narrow Aisle Truck 6
4. Storage area Manual Platform Truck
Personnel
5
3
5. Spare parts etc. Personnel with Doors Opening
into the Aisle from One Side
6
6. Material handling within department Personnel with Doors Opening

into the Aisle from Two Sides
8
7. Aisle space
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Course - 1 02/03/2017
Example Visual Management

A planning department for the ABC Company consists of 13 machines that perform
turning operations. Five turret lathes, six automatic screw machines, and two
chuckers are included in the planning department. Bar stock, in 8-ft bundles, is
delivered to the machines. The footprints for the machines are 412 ft2 for the
turret lathes, 414 ft2 for the screw machines, and 56 ft2 for the chuckers.
Personnel space footprints of 45 ft2 are used. Materials storage requirements are
estimatefd to be 20 ft2 per turret lathe, 40 ft2 per screw machine, and 50 ft2 per
chucker. An aisle space allowance of 13% is used. The space calculations are
summarized in the table below.
Service Requirements Area (ft2)
Work Quantity Floor Ceiling
Power Compressed Other Equipment Material Personnel Total
station Loading Height
Air
Turret 5 440 V 10 CFM 150 PSF 4 240 100 100 440
Lathe AC @ 100 psi
Screw 6 440 V 10 CFM 190 PSF 4 336 240 120 696
Machine AC @ 100 psi
Chucker 2 440 V 10 CFM 150 PSF 5 60 100 40 200
AC @ 100 psi
Net Area Required 1336
13% Aisle Allowance 174
Total Area Required 1510
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Facility Layout - Meeting 8-9

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Facility Layout - Meeting 8-9

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Course - 1 02/03/2017

Facility Layout Design TIN 314 (Course 8)

Flow, space, and activity relationship

Production Planning Department Production Planning Department

Production Planning Department

Cellular Manufacturing System

An Assembly Cellular A FLOW PROCESS

A Logistic System Segments of flow

Flow withina manufacturing facility

Flow from a manufacturing facility

The material management, material flow, and physical distribution

The Material Flow System FLOW PATTERN

Flow Within Departments: Flow Within Departments:

Flow Between Departments Flow Between Departments

Flow Between Departments Example

Vertical Flow Pattern FLOW PLANNING

Signs of a good general flow pattern

Principles of effective flow

Uninterrupted flow paths

Interrupted flow paths

Principles of effective flow Principles of effective flow

MEASURING FLOW Quantitative Flow Measurement:

Material Flow: From-To-Chart: Example with equivalent items

Relationship Chart Relationship Chart

Qualitative Flow Measurement: Activity Relationship Chart

Facility Layout Design TIN 314 (Course 9)

SPACE REQUIREMENTS WORKSTATION REQUIREMENTS

WORKSTATION REQUIREMENTS Workstation

Department Specification Tables for Aisle Allowance

6. Material handling within department Personnel with Doors Opening

Example Visual Management

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