Chapter 9

Facility Layout

Objectives of Facility Layout

Minimize material handling costs Utilize space efficiently Utilize labor efficiently Eliminate bottlenecks Facilitate communication and interaction between workers, between workers and their supervisors, or between workers and customers Reduce manufacturing cycle time or customer service time

Objectives of Facility Layout

Eliminate waste or redundant movement Facilitate the entry, exit, and placement of material, products, or people Incorporate safety and security measures Promote product and service quality Encourage proper maintenance activities Provide a visual control of operations or activities Provide flexibility to adapt to changing conditions Increase capacity

Basic Types of Layouts

Process Layout
Machines grouped by process they perform

Product Layout
Linear arrangement of workstations to produce a specific product

Fixed Position Layout

Used in projects where the product cannot be moved

Manufacturing Process Layout

Lathe Department Milling Department Drilling Department

L L L L L

L L L L L

M M

M M

D D

D D

D D

D D

G G

G G
Grinding Department Receiving and Shipping

G G

P P
Painting Department

A
Assembly

A Product Layout
In

Out

Comparison Of Product And Process Layouts

PRODUCT LAYOUT 1. Description 2. Type of Process Sequential arrangement of machines Continuous, mass production, mainly assembly Standardized made to stock Stable High Special purpose Limited skills PROCESS LAYOUT Functional grouping of machines Intermittent, job shop batch production, mainly fabrication Varied, made to order Fluctuating Low General purpose Varied skills

3. Product
4. 5. 6. 7. Demand Volume Equipment Workers

Comparison Of Product And Process Layouts

PRODUCT LAYOUT 8. Inventory 9. Storage space 10. Material handling 11. Aisles 12. Scheduling 13. Layout decision 14. Goal 15. Advantage Low in-process, high finished goods Small Fixed path (conveyor) Narrow Part of balancing Line balancing Equalize work at each station Efficiency PROCESS LAYOUT High in-process, low finished goods Large Variable path (forklift) Wide Dynamic Machine location Minimize material handling cost Flexibility

Fixed-Position Layouts
Typical of projects Equipment, workers, materials, other resources brought to the site Highly skilled labor Often low fixed costs Typically high variable costs

Line Balancing
Precedence diagram
Network showing order of tasks and restrictions on their performance

Cycle time
Maximum time product spends at any one workstation

Line Balancing
Precedence diagram example Cycle time
Network showing order of tasks = production time available restrictions Cd anddesired units of output on their performance

Cycle time Cd =

Maximum time product spends at any 480 one Cd = 120 = 4 minutes workstation

(8 hours x 60 minutes / hour) (120 units)

Flow Time vs Cycle Time

Cycle time = max time spent at any station Flow time = time to complete all stations

Flow Time vs Cycle Time

Cycle time = max time spent at any station Flow time = time to complete all stations
1
4 minutes

2
3 minutes

3
4 minutes

Flow time = 4 + 4 + 4 = 12 minutes Cycle time = max (4, 3, 4) = 4 minutes

Line Balancing
WORK ELEMENT A B C D Press out sheet of fruit Cut into strips Outline fun shapes Roll up and package PRECEDENCE A A B, C TIME (MIN) 0.1 0.2 0.4 0.3

Line Balancing
WORK ELEMENT A B C D Press out sheet of fruit Cut into strips Outline fun shapes Roll up and package 0.2 PRECEDENCE A A B, C TIME (MIN) 0.1 0.2 0.4 0.3

B
0.1 A

D 0.3

C
Example 5.2

0.4

Line Balancing
WORK ELEMENT A B C D Press out sheet of fruit Cut into strips Outline fun shapes Roll up and package 0.2 PRECEDENCE A A B, C TIME (MIN) 0.1 0.2 0.4 0.3

B 40 hours x 60 minutes / hour 2400 Cd = = = 0.4 minute 6,000 units 6000 0.1 A D 0.3 0.1 + 0.2 + 0.3 + 0.4 1.0 N= = = 2.5 workstations 0.4 0.4 C 0.4 Example 5.2

Line Balancing
WORK ELEMENT A B C D Press out sheet of fruit Cut into strips Outline fun shapes Roll up and package 0.2 PRECEDENCE A A B, C TIME (MIN) 0.1 0.2 0.4 0.3

B 40 hours x 60 minutes / hour 2400 Cd = = = 0.4 minute 6,000 units 6000 0.1 A D 0.3 0.1 + 0.2 + 0.3 + 0.4 1.0 N= = = 2.5 workstations 0.4 0.4 3 workstations C 0.4 Example 5.2

Line Balancing
WORK ELEMENT A B C D Press out sheet of fruit Cut into strips Outline fun shapes Roll up and package 0.2 PRECEDENCE A A B, C TIME (MIN) 0.1 0.2 0.4 0.3 Cd = 0.4 N = 2.5

B
0.1 A

D 0.3

0.4

Line Balancing

0.2

B
0.1 A

Cd = 0.4 N = 2.5

D 0.3

0.4

Line Balancing

0.2

B
0.1 A

Cd = 0.4 N = 2.5

D 0.3

0.4

Line Balancing

0.2

B
0.1 A

Cd = 0.4 N = 2.5

D 0.3

0.4

Line Balancing
Work station 1 Work station 2 Work station 3

A, B
0.3 minute

C
0.4 minute

D
0.3 minute

0.2

B
0.1 A

Cd = 0.4 N = 2.5

D 0.3

0.4

Efficiency of Line
Efficiency Minimum number of workstations

t
E = nC a
where
i=1

t
N=
i=1

Cd

ti j n Ca Cd

= completion time for element i = number of work elements = actual number of workstations = actual cycle time = desired cycle time

Line Balancing
Work station 1 Work station 2 Work station 3

A, B
0.3 minute

C
0.4 minute

D
0.3 minute

0.2

Cd = 0.4 N = 2.5

1.0 0.1 + 0.2 + 0.3 + 0.4 0.1 A E= = = 0.833 = 83.3% D 0.3 1.2 3(0.4)

0.4

Line Balancing Process

1. Draw and label a precedence diagram. 2. Calculate the desired cycle time required for the line. 3. Calculate the theoretical minimum number of workstations. 4. Group elements into workstations, recognizing cycle time and precedence constraints. 5. Calculate the efficiency of the line. 6. Stop if theoretical minimum number of workstations or an acceptable efficiency level reached. If not, go back to step 4.

Process Layout Example

Arrange six departments in a factory to minimize the material handling costs. Each department is 20 x 20 feet and the building is 60 feet long and 40 feet wide.
1. Construct a from-to matrix

2. Determine the space requirements

3. Develop an initial schematic diagram 4. Determine the cost of this layout

5. Try to improve the layout

6. Prepare a detailed plan

Process Layout Example

Number of loads per week
Department Assembly Painting (1) (2) Assembly (1) Painting (2) Machine Shop (3) Receiving (4) Shipping (5) Testing (6) Machine Receiving Shop (3) (4) Shipping (5) Testing (6)

50

100 30

0 50 20

0 10 0 50

20 0 100 0 0

Figure 9.4

Process Layout Example

Room 1 Room 2 Room 3 Assembly Department (1) Painting Department (2) Machine Shop Department (3) 40 Receiving Department (4) Shipping Department (5) Testing Department (6)

Figure 9.5

Room 4

Room 5 60

Room 6

Process Layout Example

Cost =
Cost = + +
n

Xij Cij

i=1 j=1

$50 + $200 + $40 (1 and 2) (1 and 3) (1 and 6) $30 + $50 + $10 (2 and 3) (2 and 4) (2 and 5) $40 + $100 + $50 (3 and 4) (3 and 6) (4 and 5)

= $570

Process Layout Example

Interdepartmental Flow Graph
100

50

2 10

30

100

50

5
Figure 9.6

Process Layout Example

Cost =
Cost = + +
n

Xij Cij

i=1 j=1

$50 + $100 + $20 (1 and 2) (1 and 3) (1 and 6) $60 + $50 + $10 (2 and 3) (2 and 4) (2 and 5) $40 + $100 + $50 (3 and 4) (3 and 6) (4 and 5)

= $480

Process Layout Example

Interdepartmental Flow Graph
30

50

100

50 50

100

5
Figure 9.7

Process Layout Example

Room 1 Room 2 Room 3 Painting Department (2) Assembly Department (1) Machine Shop Department (3) 40 Receiving Department (4) Shipping Department (5) Testing Department (6)

Figure 9.8

Room 4

Room 5 60

Room 6

Using Excel OM
Use Operations Layout Macro # of departments should be # of rooms Input flows as given Make sure distance table is symmetric To model adjacency, put a distance of 1 for non-adjacent departments, 0 for adjacent departments Or use regular distance

Relationship Diagramming
Used when quantitative data is not available Muthers grid displays preferences Denote location preferences with weighted lines

Relationship Diagramming Example

Production Offices

Stockroom
Shipping and receiving Locker room

Toolroom

Relationship Diagramming Example A Absolutely

E Production

O
Offices

A
U I O A X E A

I O U X

necessary Especially important Important Okay Unimportant Undesirable

Stockroom
Shipping and receiving Locker room

U
U O O O

Toolroom

Relationship Diagrams
(a) Relationship diagram of original layout

Offices

Locker room

Shipping and receiving

Stockroom

Toolroom

Key: A E I Production O U X

Figure 5.6

Relationship Diagrams
(b) Relationship diagram of revised layout
Stockroom

Offices

Shipping and receiving

Toolroom

Production

Locker room

Key: A E I O U X

Figure 5.6

Using Excel OM
Operations Layout Macro can be used for Relationship Diagrams too Make distance table like before For flows table, use dummy flows:
A = 100,000 E = 10,000 I = 1,000 O = 100 U = 10 X=0