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1
Lecture Outline
• Capacity Planning
• Basic Layouts
• Designing Process Layouts
• Designing Service Layouts
• Designing Product Layouts
• Hybrid Layouts
• Process layouts
• group similar activities together according to process
or function they perform
• Product layouts
• arrange activities in line according to sequence of
operations for a particular product or service
• Fixed-position layouts
• are used for projects in which product cannot be
moved
Women’s
Shoes Housewares
lingerie
In
Out
7-16
Designing Process Layouts
Nonadjacent Loads
2 3 200 loads
110+40=150
2 4 150 loads
1 3 110 loads 110
1 2 100 loads
4 5 60 loads 100 200
1 2 3
3 5 50 loads
2 5 50 loads 150 50 50
3 4 40 loads 60
4 5
1 4 0 loads
1 5 0 loads Grid 1
40
• Block Diagram
• type of schematic layout diagram; includes space requirements
(a) Initial block diagram (b) Final block diagram
1 4
1 2 4 2
3 5 3 5
Key: A
E
I
Stockroom Toolroom Production
O
U
X
Stockroom
Offices Shipping
and
receiving
Locker Key: A
Toolroom Production
room E
I
O
U
X
• CRAFT
• Computerized Relative Allocation of Facilities Technique
• CORELAP
• Computerized Relationship Layout Planning
• PROMODEL and EXTEND
• visual feedback
• allow user to quickly test a variety of scenarios
• Three-D modeling and CAD
• integrated layout analysis
• available in VisFactory and similar software
• Objective
• Balance the assembly line
• Line balancing
• tries to equalize the amount of work at each
workstation
• Precedence requirements
• physical restrictions on the order in which operations
are performed
• Cycle time
• maximum amount of time a product is allowed to
spend at each workstation
1 2 3
4 minutes 4 minutes 4 minutes
t
i=1
i t
i=1
i
E= nCa
N= Cd
where
ti = completion time for element i
j = number of work elements
n = actual number of workstations
Ca = actual cycle time
Cd = desired cycle time
j
Balance delay
total idle time of line = nCa -
t
i=1
i
0.2
B
0.1 A D 0.3
C
0.4
0.2
B Cd = 0.4
0.3 N = 2.5
0.1 A D
C
0.4
• Cellular layouts
• group dissimilar machines into work centers (called cells) that
process families of parts with similar shapes or processing
requirements
• Production flow analysis (PFA)
• reorders part routing matrices to identify families of parts with
similar processing requirements
• Flexible manufacturing system
• automated machining and material handling systems which can
produce an enormous variety of items
• Mixed-model assembly line
• processes more than one product model in one line
4 6 7 9
5 8
2 10 12
1 3 11
A B C Raw materials
Machines
Parts 1 2 3 4 5 6 7 8 9 10 11 12
A x x x x x
B x x x x
C x x x
D x x x x x
E x x x
F x x x
G x x x x
H x x x
Figure 5.8
Copyright 2011 John Wiley & Sons, Inc. 7-45
Revised Cellular Layout
Assembly
8 10 9 12
11
4 Cell 1 Cell 2 6 Cell 3
7
2 1 3 5
A B C
Raw materials
D E
(a) Balanced for a straight line (b) Balanced for a U-shaped line
A,B C,D E
A,B
9 min 12 min 3 min
24 24
Efficiency = = = .6666 = 66.7 % C,D
3(12) 36
24 24 12 min 12 min
Efficiency = = = 100 %
2(12) 24