Facility Layout

Layout planning in manufacturing and service organization deals with

the physical arrangement of various resources that are available in the system with an objective to improve the performance of the operating system thereby providing better service.

Minimize material-handling costs Utilize space efficiently Utilize labor efficiently Eliminate bottlenecks Facilitate communication and interaction Reduce manufacturing cycle time Reduce customer service time Eliminate wasted or redundant movement Increase capacity Facilitate entry, exit, and placement of material, products, and people Incorporate safety and security measures Promote product and service quality Encourage proper maintenance activities Provide a visual control of activities Provide flexibility to adapt to changing conditions

The relationship between volume-variety-flow provides crucial inputs to the layout problem.
Variety Very low variety Flow attributes Volume attributes Examples of operating system Types of layout used Medium Variety Multiple flow paths Mid-volume Batch manufacturing firms Group technology layout High Variety Disorganised flow Low Job shops, Customized service Process layout One-off Executive Jumbled flow One piece

Stream lined flow

High

Process industry, Mass product/ service provider

Line layout: Product layout

Project shops

Fixed position layout

TYPES OF LAYOUT 1. Process Layout

Arrangement of resources on the basis of process characteristics of the resources available. Sequence of visits for a product to different machines depends on routing. When number of jobs to be processed in large then there will be enormous amount of crossings in the flow of jobs. This poses challenges in material handling and production control.

Lathe Department

Milling Department

Drilling Department

L L L L L

L L L L L

G G

G G
Grinding Department Receiving and Shipping

G G

P P
Painting Department

A
Assembly

2. Product Layout
The order in which resources are placed exactly follows the visiting sequence of the product as per routing information. The required set of resources for every product is made available in a dedicated fashion. Material handling and production control issues are simpler.

Product A

G Product B

G Product C

PROCESS LAYOUT Sharing of specialized and costly equipment More Flexibility Less vulnerable to breakdowns

PRODUCT LAYOUT Standardized product/ Process routing Operational control simpler High output rate is possible Low tolerance for breakdown Duplication of equipments leading to high capital costs Less flexibility due to dedicated resources

ADVANTAGES

DISADVANTAGES Large inventory buildup Operational control is difficult Excess material handling

3. GROUP TECHNOLOGY LAYOUT

Configuring resources that have mid-volume, midvariety product portfolios. GT is a philosophy that seeks to exploit commonality in manufacturing and uses this as the basis for grouping components and resources. The implementation of GT is often known as cellular manufacturing. In cellular manufacturing, the available components are grouped into part families & corresponding to each part family, machine groups are identified. Production Planning and Control (PPC) becomes simpler.

Assembly

5 2 1 3 1 0

8 12 11

Raw materials

Assembly

10

12
11

Cell 1

Cell 2

Cell 3 7

A B C Raw materials

4. FIXED POSITION LAYOUT

Product manufactured is bulky, difficult to move and if often made in one or a few pieces. The specific orientation of the product will dictate the placement of specific resources required for the process.

Designing Process Layouts

Goal: 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

Block Diagramming
Unit load

STEPS

quantity in which material is normally moved

distance farther than the next block

Nonadjacent load

create load summary chart calculate composite (two way) movements develop trial layouts minimizing number of nonadjacent loads

Block Diagramming: Example

Load Summary Chart
1 2 3 FROM/TO DEPARTMENT

Department 1 1 2 3 4 5
60

2 100
100

3 50 200
50

4
50 40

50 60

Block Diagramming: Example (cont.)

2 2 1 1 4 3 2 3 1 1 3 4 3 2 5 5 5 4 4 5 200 loads 150 loads 110 loads 100 loads 60 loads 50 loads 50 loads 40 loads 0 loads 0 loads

Nonadjacent Loads: 110+40=150 0

110 100

150 200

3 4

4
Grid 2 1

150 200 50 40 60 50 50 110 50 60

3 5

40

Relationship Diagramming
Schematic diagram that uses weighted lines to denote location preference Grid
format for displaying manager preferences for department locations

Relationship Diagramming
Production

A E I O U X

Absolutely necessary Especially important Important Okay Unimportant Undesirable

O
Offices

A U I O A U X U E A

Stockroom Shipping and receiving Locker room

U
O O

Toolroom

Relationship Diagrams: Example (cont.)

(a) Relationship diagram of original layout

Offices

Locker room

Shipping and receiving

Stockroom

Toolroom

Key: A E I Production O U X

Relationship Diagrams: Example (cont.)

(b) Relationship diagram of revised layout

Stockroom

Offices

Shipping and receiving

Toolroom

Production

Locker room

Key: A E I O U X

Computerized layout Solutions

CRAFT

Computerized Relative Allocation of Facilities Technique

Computerized Relationship Layout Planning visual feedback allow user to quickly test a variety of scenarios integrated layout analysis available in VisFactory and similar software

CORELAP

PROMODEL and EXTEND

Three-D modeling and CAD

Designing Product Layouts

Line Balancing technique is employed for designing of product layouts Estimation of exact number of resources and the sequence of resources required Tasks are optimally combined without violating precedence constraints and certain number of workstations designed to complete the tasks Tries to equalize the amount of work at each station

available work time Cycle time Actual production

Number of theoretica l workstatio ns, N T

task times Cycle time

Average Resources utilization

Total task time (N A stations) cycle time

Line Balancing Example

Task Time Required Precedes (in min.) A 2.2 B, C, D B 3.4 E C 1.7 E D 4.1 F E 2.7 F F 3.3 G G 2.6 --

Company operates one shift per day Available time per shift is 450 minutes Production rate is 75 units/day

Cycle time = 450/75 = 6 minutes/part

NT = 20/6 = 3.33 = 4 stations

Precedence Diagram
B

E
A C

Task Assignment
Time Station Avail. 1 6.0 3.8 0.4 2 6.0 1.9 0.2 3 4 6.0 3.3 6.0 Elig. Tasks A C,D C,D C E E F G Will Task Idle Fit? Assign. Time A A B -D C -E F G 0.0 3.4 0.2 0.4 -C,D C -E F G

B,C,D B,C

Line Balancing Solution

Station 3 Station 1 B E A C Station 2 D F

Station 4 G

Designing GT Layouts
Production Flow Analysis

Part family identification and machine cell formation. Data required: Part Number and their Operations part-machine incidence matrix Rank Order Clustering to find logical groupings.

Example: PFA Chart or Part-Machine Incidence Matrix

Mach ines Parts

A 1

D 1

H 1

1
2 3 4 5 6 7

1 1 1 1 1 1 1 1 1 1 1

1 1

Mac hine s

Parts 28 A 27 B 26 C 25 D 1 24 E 23 F 22 G 21 H 1 20 I

Decim al equiv alent 290

Rank

2
3 4 5 1 1 1

1
1 1 1

1
1

17
81 136 258

7
5 4 2

6
7 1

1
1 1

65
140

6
3

Mac hine s

Parts 28 A 27 B 26 C 25 D 1 24 E 23 F 22 G 21 H 1 20 I

Decim al equiv alent 290

Rank

5
7 4 3

1
1 1 1 1 1 1 1

258
140 136 1 81

2
3 4 5

6
2

1
1

1
1

65
17

6
7

Machines A 1 5 7 4 3 6 2 Decimal equivalent Rank 96 1 24 4 6 8 64 3 1 1 1 1 1 1 B C D 1

Parts E F G H 1 1 1 1 1 1 1 1 5 9 24 5 16 6 96 2 1 7 7 1 I

Binary Values 26 25 24 23 22 21 20

Machines A 1 5 7 4 3 6 2 Decimal equivalent Rank 96 1 96 2 64 3 24 4 1 1 H 1 1 1 1 D 1 B

Parts F G I C E

Binary Values 26 25

1 1

24 23 1 1 1 1 1 1 6 8 5 9 1 22 21 20

24 5

16 6

7 7

Machines A 1 5 7 4 3 6 2 Decimal equivalent Rank 96 1 96 2 64 3 24 4 1 1 H 1 1 1 1 D 1 B

Parts F G I C E

Binary Values 26 25

1 1

24 23 1 1 1 1 1 1 6 8 5 9 1 22 21 20

24 5

16 6

7 7