Facility Layout

Facility Layout
A layout is a physical configuration of departments, workstations, equipments in the conversion process. It is a special arrangement of physical resources used to create products or deliver services Right layout for organisation will improve productivity, the quality of product or service, delivery rates.

Objectives
High equipment utilisation Minimisation of delay Reduced manufacturing time Minimum material handling, damage and spoilage Effective space utilisation Reduced in process inventory Better supervision and control Worker convenience Reduced congestion of materials, machinery & men Flexibility Health & Safety

Basic principles for designing a layout

Existing products

ce n ue q e s flow s ion rial t a er ate p O &m

Sto rag e sy & ha ste nd ms lin

Future activities

Space Available
He alt h &
nts e ipm used u Eq b to

Sa

fet y

Cost considerations while designing a layout

1. 2. 3. 4. 5. 6. 7. Material movement cost Cost of space Production delays Material spoilage Labour dissatisfaction & health risk Poor quality & service Possible changes in future

Basic Types of Layout

1. Process Layout 2. Product Layout 3. Fixed position layout

Basic Layouts
Assembling 1 2 3 4

Stores

7 Painting Receiving Office

1 Turning 2 Milling 3 Grinding 4 Painting 5 Assembling 6 Packing 7 - Shipping Fig - Product Layout Grinding

Turning

Milling

Machine Raw Material Tools Workmen

Shipping

Fig - Process Layout

Fig Fixed Position Layout

Process Layout
1. 2. 3. 4. 5. 6. Merits Higher variety Flexibility Machine breakdown doesnt cause production halt Less maintenance staff Higher job satisfaction Supervision is simple 1. Demerits Higher flow times Intermittent flow More set-ups PPC is complex High worker skills Higher inventories More material handling

1. 2. 3. 4.

Product Layout
1. Merits Low total flow time No stoppages Repetitive jobs Minimum set-ups PPC is simple Less inspection required Low worker skills Lower inventories High resource utilisation 1. 2. 3. 4. 5. 6. 7. Demerits Low or no variety Less Flexibility High stoppage cost if any of the equipment breaks down More maintenance staff Monotonous work Higher capital investment as more machines required More space needed

1. 2. 3. 4. 5.

Cellular Manufacturing / Group Technology

Total Production Time

2%

5% Transport, Idle and waiting time

Productive Time (38%)

Set-up and necessary non value adding time Total Machining Time

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Cellular Manufacturing / Group Technology

Production can be done in small batches taking advantages of flow characteristics of product layout Machines used to produce a particular component are grouped together These grouped machines are placed in small sections called cells In cellular manufacturing one can use the benefits of both the traditional ways of facility layout

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Cellular Manufacturing
D Cell 1 L L L G Cell 5 M M Cell 3 D G G
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G Cell 4 M

M Milling D Drilling G Grinding L - Lathe

L Cell 2

D L

L Cell 6

Designing rules
Cell size

It should have sociable number of employees Comfortable work conditions Visible control possible One component in each cell Independent operational sequence Internal routing flexibility Ability to accommodate new parts

Cell independency

Cell flexibility

Analysis of each component No partial implementation

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Benefits of Cellular manufacturing

Reduced flow time due to less halts Unnecessary fresh set-ups or modifications eliminated Lower inventories Variety available Employees are empowered and satisfied Improved quality, cycle time, customer satisfaction Can accommodate JIT and sudden demand changes Easier to manage, maintain and control Higher throughput

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Drawbacks
Components in one cell should be identical to reduce setup times An ill shaped Cellular layout will have to keep more inventory Improper design may result in idle time Improper training and education can spoil the purpose Cellular Manufacturing is the answer to growing consumer demands for variety of products at acceptable prices & on time
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