Lesson 9 - Layout and Flow

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Chapter 7 Layout and flow
Pearson Education Ltd. Rob Judges
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Slack, Chambers and Johnston, Operations Management, 6th Edition, Nigel Slack, Stuart Chambers, and Robert Johnston 2010
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Layout and flow

,"erations strateg# !rocess design
Su""l# net$ork design %a#out %a#out &lo$ and .lo$ !eo"le, 'obs and organi(ation !roduct)ser*ice design
+esign !lanning and control
-m"ro*ement
!rocess technolog#
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Key Teaching Ob ecti!es

0 1o introduce the t$o conce"ts o. "rocess t#"e and la#out t#"e and the relationshi" bet$een them 0 1o describe the basic la#out t#"es in terms o. the nature o. the .lo$ o. trans.ormed resources through the "rocess 0 1o stress that most real la#outs are h#brids o. the "ure t#"es 0 1o identi.# some o. the sim"le a""roaches that can be used to determine the e2act nature o. a la#out
7/
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Key operations "uestions

-n Cha"ter 7 4 %a#out and .lo$4 Slack et al identi.# the .ollo$ing ke# 5uestions6 07hat is la#out8 07hat are the basic la#out t#"es used in o"erations8 07hat t#"e o. la#out should an o"eration choose8 09o$ should each basic la#out t#"e be designed in detail8
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7:
Layout in!ol!es the relati!e positioning of transfor#ed resources within operations and the allocation of tas$s% which together dictate the flow of transfor#ed resources
1he relati*e "ositioning o. trans.orming resources

;i e deciding $here to "ut all the .acilities, machines, e5ui"ment and sta.. in the o"eration<
1he allocation o. tasks to trans.orming resources
1he .lo$ o. trans.ormed resources

;i e the materials, in.ormation and customers
7:
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Tesco store&s flow process

'hat layout type is a con!entional super#ar$et and how does it differ fro# a #anufacturing operation using the sa#e layout type(
Essentiall#, a su"ermarket uses a .unctional la#out Each area o. the su"ermarket can be seen as being e5ui*alent to a $orkstation or machine in a manu.acturing o"eration 1he trans.ormed resource ;customers< .lo$s bet$een *arious areas de"ending on their indi*idual needs So each customer $ill take a ;sometimes marginall#< di..erent route through the o"eration 1he biggest di..erence bet$een the su"ermarket and an e5ui*alent manu.acturing o"eration concerns the ob'ecti*es o. the la#out -n con*entional manu.acturing o"erations, the ob'ecti*e is usuall# to minimi(e the distance tra*elled in ;or time taken to get through< the o"eration =# contrast, a su"ermarket>s la#out is intended to ma2imi(e sales 1his is not al$a#s the same as ma2imi(ing the distance tra*elled ;or time taken to get through< the o"eration, but it $ill certainl# in*ol*e a greater time s"ent looking at, and ho"e.ull# bu#ing, "roducts
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'hat is a layout(
0 1he ?la#out> o. an o"eration or "rocess means ho$ its trans.ormed resources are "ositioned relati*e to each other and ho$ its *arious tasks are allocated to these trans.orming resources 0 1ogether these t$o decisions $ill dictate the "attern o. .lo$ .or trans.ormed resources as the# "rogress through the o"eration or "rocess
'hy is layout decisions i#portant

0 %a#out is an im"ortant decision because, i. the la#out "ro*es $rong, it can lead to o*er@long or con.used .lo$ "atterns, customer 5ueues, long "rocess times, in.le2ible o"erations, un"redictable .lo$ and high cost 0 Also, re@la#ing out an e2isting o"eration can cause disru"tion, leading to customer dissatis.action or lost o"erating time
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7B
'hat #a$es a good layout(

C Inherent safety All "rocesses $hich might constitute a danger to either sta.. or customers should not be accessible to the unauthori(ed C Length of flow 1he .lo$ o. materials, in.ormation or customers should be a""ro"riate .or the o"eration 1his usuall# means minimi(ing the distance tra*elled b# trans.ormed resources C Clarity of flow All .lo$ o. materials and customers should be $ell sign"osted, clear and e*ident to sta.. and customers alike C Staff conditions Sta.. should be located a$a# .rom nois# or un"leasant "arts o. the o"eration C Management coordination Su"er*ision and communication should be assisted b# the location o. sta.. and communication de*ices C Accessibility. All machines and .acilities should be accessible .or "ro"er cleaning and maintenance C Use of space All la#outs should use s"ace a""ro"riatel# 1his usuall# means minimi(ing the s"ace used, but sometimes can mean achie*ing an im"ression o. s"acious lu2ur#, as in the entrance lobb# o. a high@class hotel C Long-term flexibility. %a#outs need to be changed "eriodicall# A good la#out $ill ha*e been de*ised $ith the "ossible .uture needs o. the o"eration in mind
7B
7D
The four basic layout types

Eost "ractical la#outs are deri*ed .rom onl# .our basic layout types6
1 &i2ed@"osition la#out
0 -n .i2ed@"osition la#out the trans.ormed resources do not mo*e bet$een the trans.orming resources -nstead o. materials, in.ormation or customers .lo$ing through an o"eration, the reci"ient o. the "rocessing is stationar# and the e5ui"ment, machiner#, "lant and "eo"le $ho do the "rocessing mo*e as necessar# 0 1his could be because the "roduct or the reci"ient o. the ser*ice is too large to be mo*ed con*enientl#, or it might be too delicate to mo*e, or "erha"s it could ob'ect to being mo*edF .or e2am"le6

Motorway construction the "roduct is too large to mo*e. Open-heart surgery "atients are too delicate to mo*e. High-class service restaurant customers $ould ob'ect to being mo*ed to $here .ood is "re"ared Shipbuilding the "roduct is too large to mo*e. Mainframe computer maintenance the "roduct is too big and "robabl# also too delicate to mo*e, and the customer might ob'ect to bringing it in .or re"air
7D
7 10

2 &unctional la#out
0 &unctional la#out is so called because it con.orms to the needs and con*enience o. the .unctions "er.ormed b# the trans.orming resources $ithin the "rocesses 0 -n .unctional la#out, similar resources or "rocesses are located together 1his ma# be because it is con*enient to grou" them together, or that the utili(ation o. trans.orming resources is im"ro*ed -t means that $hen materials, in.ormation or customers .lo$ through the o"eration, their route is determined according to their needs +i..erent "roducts or customers $ill ha*e di..erent needs and there.ore take di..erent routes E2am"les o. .unctional la#outs include6
C Hospital some processes (e.g. X-ray machines and laboratories are re!uired by several t#"es o. "atientF some "rocesses ;e g general $ards< can achie*e high sta..@ and bed@utili(ation C Machining the parts which go into aircraft engines some processes (e.g. heat treatment need s"ecialist su""ort ;heat and .ume e2traction<F some "rocesses ;e g machining centres< re5uire the same technical su""ort .rom s"ecialist setter4o"eratorsF some "rocesses ;e g grinding machines< get high machine utili(ation as all "arts $hich need grinding "ass through a single grinding section C Supermar"et some products# such as tinned goods# are convenient to restoc" if grouped together Some areas, such as those holding .ro(en *egetables, need the common technolog# o. .ree(er cabinets ,thers, such as the areas holding .resh *egetables, might be together because that $a# the# can be made to look attracti*e to customers
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7 11
)unctional layout in a library * the path of one custo#er

%oan books in sub'ect order ,n@line and C+@R,E access room
Stud# desks
Com"an# re"orts En5uiries
1o 'ournal stack
Current 'ournal s Reser*e collection
Re.erence section
Store room Counter sta..
Co"#ing area
Entrance
7 11
E2it
7 12

/ Cell la#out
0 A cell la#out is one $here the trans.ormed resources entering the o"eration are "re@selected ;or "re@select themsel*es< to mo*e to one "art o. the o"eration ;or cell< in $hich all the trans.orming resources, to meet their immediate "rocessing needs, are located 0 Cell la#out is an attem"t to bring some order to the com"le2it# o. .lo$ $hich characteri(es .unctional la#out E2am"les o. cell la#outs include6
C Some laptop assembly within a contract manufacturer$s factory# the assembly of different la"to" brands ma# be done in a s"ecial area dedicated to that one brand that has s"ecial re5uirements such as "articularl# high 5ualit# le*els C %&unch$ products area in a supermar"et some customers use the supermar"et 'ust to "urchase sand$iches, sa*our# snacks, etc .or their lunch 1hese "roducts ma# be located together so that these customers do not ha*e to search around the store C Maternity unit in a hospital customers needing maternity attention are a well-defined grou" $ho can be treated together and $ho are unlikel# to need the other .acilities o. the hos"ital at the same time that the# need the maternit# unit
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7 1/
+epart#ent store with sports goods ,shop-within-a-shop&

=ooks and *ideo s
&oot$e ar !er.ume and 'e$eller#
S"orts sho"
Eens$ear
Entrance
Con.ectioner #, ne$s"a"er, maga(ines and stationer#
Ele*ators 7omen>s clothes
Entrance
%uggag e and gi.ts
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7 13

3 !roduct la#out
0 !roduct la#out in*ol*es locating the trans.orming resources entirel# .or the con*enience o. the trans.ormed resources 0 Each "roduct, "iece o. in.ormation or customer .ollo$s a "rearranged route in $hich the se5uence o. acti*ities that are re5uired matches the se5uence in $hich the "rocesses ha*e been located 0 1he trans.ormed resources ?.lo$> as in a ?line> through the "rocess 1his is $h# this t#"e o. la#out is sometimes called .lo$ or line layout 0 &lo$ is "redictable and there.ore relati*el# eas# to control E2am"les o. "roduct la#out include6
C (utomobile assembly almost all variants of the same model re!uire the same se!uence of "rocesses C &oan application processing all applications re!uire the same se!uence of clerical and decision@making acti*ities C Self-service cafeteria generally the se!uence of customer re!uirements (starter# main course, dessert, drink< is common to all customers, but la#out also hel"s control customer .lo$
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7 1:
Product flow in Cadbury&s

&lo$ o. chocolate in Cadbur#>s .actor# &lo$ o. customers in Cadbur# 7orld
=oth Cadbur#>s chocolate .actor# and its ?Cadbur# 7orld> *isitor attraction use ?"roduct> la#out =ut $hat $ill be di..erent about the la#outs and $h#8
7 1:
7 16
.n ar#y induction centre which uses product layout
%ecture theatre
7aiting area
7aiting area
+octor Gni.orm issuing area +octor
+octor
=lood test H@ra# =lood test H@ra# =lood test H@ra# Records6 "ersonal histor# and medical details
+octor
Gni.orm store
+octor
+octor
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7 17
. product layout in a paper #anufacturing operation
7 17
7 1B
.n inno!ati!e layout in a surgery i#pro!es its efficiency
7 1B
7 1D
)actory flow helps surgery producti!ity

'hat do you thin$ are the ad!antages and disad!antages of this arrange#ent when co#pared with the con!entional layout of one surgeon re#aining in one operating theatre( 1he .irst "oint to make here is that, essentiall#, the la#out has not changed as such =oth a con*entional o"erating theatre and the arrangement described in the short case are ?.i2ed "osition> la#outs 7hat has changed is that, t$o "atients are mo*ed in and out o. their o"erating theatres ;the .i2ed "ositions< in order .or "re"aration $ork that does not in*ol*e the surgeon to be carried out $hilst the surgeon is o"erating on the other "atient 1his has the ad*antage o. utili(ing $hat "resumabl# is the scarce resource ;the surgeon< e*en though t$o o"erating theatres are no$ needed 1o some e2tent, it is mo*ing to$ards the "rinci"les o. .lo$ "rocesses because, although the "atient does not mo*e as such, the# do mo*e relati*e to the surgeon
7 1D
7 20
/i0ed layout1 . restaurant co#ple0 with all four basic layout types
Cell la#out bu..et &i2ed@"osition la#out ser*ice restaurant

+essert bu..et Starter bu..et
%ine la#out ca.eteria

Ser*ice line ,*en !re"aration
Eain course bu..et
&unctional la#out kitchen

Cool room &ree(er Iegetable "re" Jrill
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7 21
2electing a layout
0 1he im"ortance o. .lo$ to an o"eration $ill de"end on its !olu#e and !ariety characteristics. 0 7hen *olume is *er# lo$ and *ariet# is relati*el# high, ?.lo$> is not a ma'or issue and a .i2ed@"osition man# be suitable 0 7ith higher *olume and lo$er *ariet#, .lo$ becomes an issue 0 -. the *ariet# is still high, ho$e*er, an entirel# .lo$@dominated arrangement is di..icult because there $ill be di..erent .lo$ "atterns 0 7hen the *ariet# o. "roducts or ser*ices reduces to the "oint $here a distinct ?categor#> $ith similar re5uirements becomes e*ident but *ariet# is still not small, cell la#out could become a""ro"riate 0 7hen *ariet# is relati*el# small and *olume is high, .lo$ can become regulari(ed and a "roduct@based la#out is likel# to be a""ro"riate, as in an assembl# "lant 0 1he *olume4*ariet# characteristics o. the o"eration $ill, to a large e2tent, narro$ the choice do$n to one or t$o la#out o"tions 0 1he decision as to $hich la#out t#"e to ado"t $ill be in.luenced b# an understanding o. their relati*e ad*antages and disad*antages
7 21
7 22
3olu#e and !ariety characteristics of layout types

9igh &lo$ is intermittent %o$ &i2ed@"osition la#out &unctional la#out Cell la#out Iariet# Iolume %o$ 9igh
!roduct la#out
Regular .lo$ more im"ortant

7 22
&lo$ becomes continuous
Regular .lo$ more .easible
7 2/
.d!antages and disad!antages of fi0ed position layout
&i2ed@"osition la#out
Ier# high "roduct and mi2 .le2ibilit#
Ad*antages
!roduct)customer not mo*ed 9igh *ariet# o. tasks .or sta.. Ier# high unit costs Scheduling s"ace and acti*ities can be di..icult
+isad*antages
7 2/
7 23
.d!antages and disad!antages of functional layout
&unctional la#out
9igh "roduct and mi2 .le2ibilit#
Ad*antages
Relati*el# robust in the case o. disru"tions Eas# to su"er*ise %o$ utili(ation
+isad*antages Can ha*e *er# high 7-!

Com"le2 .lo$
7 23
7 2:
.d!antages and disad!antages of cell layout

Cell la#out
Can gi*e good com"romise
Ad*antages
&ast through"ut Jrou" $ork can result in good moti*ation Can be costl# to rearrange e2isting la#out Can need more "lant
+isad*antages
7 2:
7 26
.d!antages and disad!antages of product layout

!roduct la#out
%o$ unit costs .or high *olume
Ad*antages
,""ortunities .or s"eciali(ation o. e5ui"ment Can ha*e lo$ mi2 .le2ibilit#
+isad*antages Not *er# robust in the case o.

disru"tions 7ork can be *er# re"etiti*e
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7 27
The relationship between process types and layout types

Eanu.acturing .unctional t#"es
!ro'ect "rocesses Jobbing "rocesses &unctional la#out =atch "rocesses Cell la#out Eass "rocesses Continuous "rocesses
=asic la#out t#"es

&i2ed@"osition la#out
Ser*ice .unctional t#"es
!ro.essional ser*ices
Ser*ice sho"s
Eass ser*ices !roduct la#out
7 27
7 2B
4asic layout types ha!e different fi0ed and !ariable costs that see# to deter#ine which one to use
Costs
&i2ed@ "osition &unctional
Cell !roduct
Gse Gse .i2ed@ .unctional "osition
Gse cell
Gse "roduct
Iolume
7 2B
7 2D
4ut uncertainty about e0act fi0ed and !ariable costs #eans the decision can rarely be #ade on cost alone
Costs
&i2ed@"osition &unctional Cell !roduct
( Gse "roduct
Gse .i2ed@"osition Gse .i2ed@"osition or .unctional Gse .unctional
Iolume
Gse .unctional or cell or "roduct Gse .unctional or cell
7 2D
7 /0
+etailed design techni"ues

,nce the basic la#out t#"e has been decided, the ne2t ste" is to decide the detailed design o. the la#out
&i2ed "osition 4 resource location anal#sis
0 1he ob'ecti*e o. the detailed design o. .i2ed@"osition la#outs is to achie*e a la#out .or the o"eration $hich allo$s all the trans.orming resources to ma2imi(e their contribution to the trans.ormation "rocess b# allo$ing them to "ro*ide an e..ecti*e ?ser*ice> to the trans.ormed sources
&unctional la#out 4 .lo$ charts and relationshi" charts Cell la#out 4 "roduct .lo$ anal#sis !roduct la#out 4 assembl# line balancing techni5ues
7 /0
7 /1
+etailed design of functional layout

0 1he detailed design o. .unctional la#outs is com"le2, as is .lo$ in this t#"e o. la#out 0 Chie. among the .actors $hich lead to this com"le2it# is the *er# large number o. di..erent o"tions 0 &or ) centres there are .actorial ) ()* different ways of arranging the centres 0 1his co#binatorial co#ple0ity of functional layouts #a$es o"timal solutions di..icult to achie*e in "ractice 0 Eost .unctional la#outs are designed b# a combination o. intuition, common sense and s#stematic trial and error 5nfor#ation re"uired before detailed design of functional layouts C 1he area re5uired b# each $ork centreF C 1he constraints on the sha"e o. the area allocated to each $ork centreF C 1he degree and direction o. .lo$ bet$een each $ork centre ;.or e2am"le, number o. 'ourne#s, number o. loads or cost o. .lo$ "er distance tra*elled<F C 1he desirabilit# o. $ork centres being close together or close to some .i2ed "oint in the la#out
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7 /2
Collecting infor#ation in functional layout
;a<
1o &rom
%,A+S)+AK
;b<
%,A+S)+AK
= 17
E A =
-. direction is not im"ortant, colla"ses to
= /0
A = C + E /0 1/
20
/0 10 20
/0
60 20
10
70 /0
C + E
/0 B0 30
- -
10 10 10 10
7 /2
7 //
Collecting infor#ation in functional layout 6Continued7
;b<
%,A+S)+AK
A A = C + E
= /0
;c< . 4 ,r, alternati*el# C + E
%,A+S)+AK
/0
60 20
/0
/0 B0 30
@ /0 60 @ 20 @ /0 B0 30
7 //
7 /3

;a<
1o &rom
%,A+S)+AK
;d<
GN-1 C,S1)+-S1ANCE 1RAIE%%E+

1o
= 17
&rom
= 2
C 2 /
+ 2 / 2
E 2 3 2 10
A = C + E /0 1/
20
/0 10 20
A =
-. cost o. .lo$ di..ers bet$een $ork centres, combine $ith
/ 2 2
10
70 /0
C + E
- -
10 10 10 2 2 2 2
10 10 10 10
7 /3
7 /:

;d< GN-1 C,S1)+-S1ANCE 1RAIE%%E+
1o &rom
;e< +A-%K C,S1)+-S1RANCE 1RAIE%%E+

1o &rom
= 2
C 2 /
+ 2 / 2
E 2 3 2 10
1o gi*e
= /3
A = C + E / 2
A = /D C + /00
60 20 60 60 130 /00
20
10 10 10 2 2 2 2
E 20 20 20 20
7 /:
7 /6

;e< +A-%K C,S1)+-S1ANCE 1RAIE%%E+
1o &rom
;.< +A-%K C,S1)+-S1RANCE 1RAIE%%E+
= /3
E A =
im"ortant, colla"ses to
= 7/
A = /D C + /00
60 20 60 60 130 -. direction is not /00
B0
/60 30 B0
20
C + E
160 /20
E 20 20 20 20
7 /6
7 /7
)unctional layout design* #ini#i8ing distance tra!elled

0 -n .unctional la#out, the "rime ob'ecti*e is to minimi(e the costs to the o"eration $hich are associated $ith .lo$ through the o"eration 0 1his means minimi(ing the total distance tra*elled in the o"eration 0 1he e..ecti*eness o. the la#out can thus be calculated .rom6 E..ecti*eness o. la#out L M+i' ,i' for all i - ' 7here6 0 +i' . the flow in loads or 'ourneys per period of time from wor" centre i to wor" centre ' 0 ,i' . the distance between wor" centre i and wor" centre '. 0 1he lo$er the e..ecti*eness score, the better the la#out
7 /7
7 /B
. relationship chart
C,+E A E , G H C%,SENESS Absolutel# necessar# Es"eciall# im"ortant -m"ortant ,rdinar# closeness Gnim"ortant Gndesirable
+E!AR1EEN1
Eetrolog# Electronic testing Anal#sis Gltrasonic testing &atigue testing -m"act testing
E E
A G , ,
, G G
H G
7 /B
7 /D
+etailed design in cell layout

-n cell la#out design a .unctional la#out is di*ided into cells, each o. $hich has the resources to "rocess a ?.amil#> o. "arts
;a< 1 1 2 9 / 3 : 6 7 B 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 Com"onent .amilies 2 / 3 : 6 7 9 9 Eachines 9 9 ;a< B 9 1 69 / B 2 : 7 / 39 Com"onent .amilies 6 B : 2 3 1 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 9 B
Eachines
!roduction .lo$ anal#sis to allocate machines to cells

7 /D
7 30
+etailed design of product layout 0 Rather than ?$here to "lace $hat>, "roduct la#out is concerned more $ith ?$hat to "lace $here> 0 %ocations are .re5uentl# decided u"on and then $ork tasks are allocated to each location 0 &or e2am"le, it ma# ha*e been decided that .our stations are needed to make com"uter cases 0 1he decision then is $hich o. the tasks that go into making the cases should be allocated to each station 0 1he main "roduct la#out decisions are as .ollo$s6
C 7hat c#cle time is needed8 C 9o$ man# stages are needed ;number o. $orkstations<8 C 9o$ should the task@time *ariation be dealt $ith8 C 9o$ should the la#out be balanced8
7 30
7 31
The cycle ti#e of product layouts

0 Cycle ti#e is the ti#e between co#pleted products% "ieces o. in.ormation or customers emerging .rom the "rocess 0 -t is calculated b# considering the likel# demand .or the "roducts or ser*ices o*er a "eriod and the amount o. "roduction time a*ailable in that "eriod
'or$ed E0a#ple
Su""ose the regional back@o..ice o"eration o. a large bank is designing an o"eration $hich $ill "rocess its mortgage a""lications 1he number o. a""lications to be "rocessed is 160 "er $eek and the time a*ailable to "rocess the a""lications is 30 hours "er $eek
C#cle time .or the la#out L 1ime A*ailable L No 1o be "rocessed 30 L 160 1 3 L 1: minutes
So the bank>s la#out must be ca"able o. "rocessing a com"leted a""lication once e*er# 1: minutes
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7 32
:u#ber of stages ; wor$stations ; :o. of wor$ers

0 1he ne2t decision concerns the number o. stages in the la#out and de"ends on the c#cle time re5uired and the total 5uantit# o. $ork in*ol*ed ;total wor$ content7 in "roducing the "roduct or ser*ice 0 The larger the total wor$ content and the smaller the re5uired c#cle time, the more stages $ill be necessar# 'or$ed E0a#ple
Su""ose the bank in the "re*ious e2am"le calculated that the a*erage total $ork content o. "rocessing a mortgage a""lication is 60 minutes 1he number o. stages needed to "roduce a "rocessed a""lication e*er# 1: minutes can be calculated as .ollo$s6
Number o. stages L total $ork content re5uired c#cle time L 60 minutes L 1: minutes 3 stages
7 32
7 3/
4alancing wor$-ti#e allocation

0 ,ne o. the most im"ortant design decisions in "roduct la#out is that o. line balancing. 0 5n the mortgage@"rocessing e2am"le $e ha*e assumed that the 1: minutes o. $ork content are allocated e5uall# to the .our stations 0 1his is nearl# al$a#s im"ossible to achie*e in "ractice and some imbalance in the $ork allocation results
'or$ed E0a#ple
-n &igure o*erlea. the $ork allocations in a .our@stage line are illustrated 1he total amount o. time in*ested in "roducing each "roduct or ser*ice is .our times the c#cle time because, .or e*er# unit "roduced, all .our stages ha*e been $orking .or the c#cle time 7hen the $ork is e5uall# allocated bet$een the stages, the total time in*ested in each "roduct or ser*ice "roduced is 3 N 2 : L 10 minutes 9o$e*er, $hen $ork is une5uall# allocated, as illustrated, the time in*ested is / 0 N 3 L 12 minutes, i e 2 0 minutes o. time, 16 67 "er cent o. the total, is $asted
7 3/
7 33
4alancing loss is that proportion of the ti#e in!ested in processing the product or ser!ice which is not used producti!ely
An ideal ?balance> $here $ork is allocated e5uall# bet$een the stages

/ 2: 2 %oad 1: 1 0: 0 1 2 / 3 C#cle time L 2 : mins 7ork allocated to stage
Stage
7 33
7 3:
4alancing loss is that proportion of the ti#e in!ested in processing the product or ser!ice which is not used producti!ely 6Continued7
=ut i. $ork is not e5uall# allocated, the c#cle time $ill increase and ?balancing losses> $ill occur
/: / 2: 2 %oad 1: 1 0: 0
C#cle time L / 0 mins
7ork allocated to stage
-dle time
6 2 2< s s 4 o l 0 O ;/ ncing < a : l a 2 b ting /04 ; a l u O c < l Ca 42/ 0 / ; L e m i t e l mins -d 0 2 e l L c#c 20 e*er# /0 L g N n i 3 c =alan 67 6 1 0 L loss 67P 6 1 L
3
Stage
7 3:
7 36
4alancing techni"ues
0 . precedence diagra# is used to assist in balancing wor$ti#e allocation. 0 This is a representation of the ordering of the elements which compose the total $ork content o. the "roduct or ser*ice 0 1his general a""roach is to allocate elements .rom the "recedence diagram to the .irst stage, starting .rom the le.t, in order o. the columns until the $ork allocated to the stage is as close to, but less than, the c#cle time 7hen that stage is as .ull o. $ork as is "ossible $ithout e2ceeding the c#cle time, mo*e on to the ne2t stage, and so on, until all the $ork elements are allocated, taking into account "recedence re5uirements 0 9euristic rules are used to decide $hich task to select .or allocation6
C Sim"l# choose the largest that $ill ?.it> into the time remaining at the stage C Choose the element $ith the most ?.ollo$ers>6 that is the highest number o. elements $hich can onl# be allocated $hen that element has been allocated
7 36
7 37
4alancing techni"ues
'or$ed E0a#ple Qarlstad Qakes ;QQ< is a manu.acturer o. s"ecialit# cakes, $hich has recentl# obtained a contract to su""l# a ma'or su"ermarket chain $ith a s"ecialit# cake in the sha"e o. a s"ace rocket -t has been decided that the *olumes re5uired b# the su"ermarket $arrant a s"ecial "roduction line to "er.orm the .inishing, decorating and "acking o. the cake 1his line $ould ha*e to carr# out the elements sho$n in .igure o*erlea., $hich also sho$s the "recedence diagram .or the total 'ob 1he initial order .rom the su"ermarket is .or :,000 cakes a $eek and the number o. hours $orked b# the .actor# is 30 "er $eek &rom this6
1he re5uired c#cle time L 30 hrs N 60 mins :,000 L 0 3B minutes
1he re5uired number o. stages L 1 6B min ;the total $ork content< L / : stages 0 3B min ;the re5uired c#cle time<
1his means .our stages are re5uired

7 37
7 3B
Precedence diagra# for Karlstad Ca$es
0 17 mins
0 /0 mins
0 2: mins
0 0: mins
0 2: mins
a
0 12 mins
c
0 /6 mins
g
0 10 mins
h
0 0B mins
7 3B
7 3D
Ele#ent listing for Karlstad Ca$es - e0a#ple
Element Element Element Element Element Element Element Element Element
a b c d e . g h i
+e@tin and trim Resha"e $ith o..@cuts Clad in almond .ondant Clad in $hite .ondant +ecorate, red icing +ecorate, green icing +ecorate, blue icing A..i2 trans.ers 1rans.er to base and "ack
0 12 mins 0 /0 mins 0 /6 mins 0 2: mins 0 17 mins 0 0: mins 0 10 mins 0 0B mins 0 2: mins
1otal $ork content L 1 6B mins
7 3D
7 :0
.llocation of ele#ents and balancing for Karlstad Ca$es

Stage 1 0 /0 mins a 0 12 mins b c 0 /6 mins Stage 2 Stage / 0 17 mins e 0 2: mins d 0 0: mins . g 0 10 mins h 0 0B mins 0 2: mins i Stage 3
<.B <.A C#cle time L 0 3B mins <.@ <.? <.> <.= < = > ? @
-dle time L ;0 3B 4 0 32< O ;0 3B 4 0 /6< O ;0 3B 4 0 32< e*er# L 0 23 mins c#cle !ro"ortion o. 0 23 idle time "er L 3 N 0 3B c#cle
L 12 :P
7 :0
7 :1
,Long and thin& !ersus ,short and fat& layouts

A 60 minute task $ith a re5uired c#cle time o. 1: minutes
cess o r " hin t @ g n o
=A =A =A =A
1 e*er# 1: minutes
60 ?< ?<
1 e*er# 1: minutes
60
?<
?<
1 e*er# 1: minutes
60
60
at . @ t r Sho
es c o r "
7 :1
7 :2
Long and thin !ersus short and fat

0%ong and short describes the number o. stages 0&at and thin describes the amount o. $ork at each stage
Ad*antages o. long@thin "rocesses controlled .lo$ sim"le materials handling lo$er ca"ital re5uirement ;no du"lication< greater e..icienc# higher s"ace utili(ation
Ad*antages o. short@.at "rocesses higher mi2 .le2ibilit# higher *olume .le2ibilit# greater robustness less monotonous higher o$nershi"
7 :2
7 :/
Calculating the re"uired cycle ti#e

=<< @C< #ins @.C #ins
+eciding how #any staff 6or stages7 are needed
&orecast +emands +uring the !eriod ;A< A*ailabilit# o. !roducti*e 1ime ;=< C#cle 1ime ;CL=)A<
7ork Content o. the 1ask ;+< C#cle 1ime Re5uired ;C< Number o. Sta.. ;+)C<
AA #ins @.C #ins ==.@B 6=>7
7 :/
7 :3
5ndi!idual .ssign#ent >

0 7eldon Case Stud#, Cha"ter 7 "age 20/ +ue B A"ril 2013 1he assignment should be handed in as a hard co"#
7 :3

Lesson 9 - Layout and Flow

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Lesson 9 - Layout and Flow

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71

Chapter 7 Layout and flow

Pearson Education Ltd. Rob Judges

Layout and flow

+esign !lanning and control

Key Teaching Ob ecti!es

Key operations "uestions

1he relati*e "ositioning o. trans.orming resources

1he allocation o. tasks to trans.orming resources

1he .lo$ o. trans.ormed resources

Tesco store&s flow process

'hy is layout decisions i#portant

'hat #a$es a good layout(

The four basic layout types

The four basic layout types

)unctional layout in a library * the path of one custo#er

Current 'ournal s Reser*e collection

The four basic layout types

+epart#ent store with sports goods ,shop-within-a-shop&

&oot$e ar !er.ume and 'e$eller#

Con.ectioner #, ne$s"a"er, maga(ines and stationer#

Ele*ators 7omen>s clothes

%uggag e and gi.ts

The four basic layout types

Product flow in Cadbury&s

.n ar#y induction centre which uses product layout

+octor Gni.orm issuing area +octor

. product layout in a paper #anufacturing operation

.n inno!ati!e layout in a surgery i#pro!es its efficiency

)actory flow helps surgery producti!ity

Cell la#out bu..et &i2ed@"osition la#out ser*ice restaurant

%ine la#out ca.eteria

Eain course bu..et

&unctional la#out kitchen

3olu#e and !ariety characteristics of layout types

Regular .lo$ more im"ortant

&lo$ becomes continuous

Regular .lo$ more .easible

.d!antages and disad!antages of fi0ed position layout

.d!antages and disad!antages of functional layout

Relati*el# robust in the case o. disru"tions Eas# to su"er*ise %o$ utili(ation

+isad*antages Can ha*e *er# high 7-!

.d!antages and disad!antages of cell layout

.d!antages and disad!antages of product layout

,""ortunities .or s"eciali(ation o. e5ui"ment Can ha*e lo$ mi2 .le2ibilit#

+isad*antages Not *er# robust in the case o.

The relationship between process types and layout types

=asic la#out t#"es

Ser*ice .unctional t#"es

Eass ser*ices !roduct la#out

Gse Gse .i2ed@ .unctional "osition

Gse .i2ed@"osition Gse .i2ed@"osition or .unctional Gse .unctional

+etailed design techni"ues

+etailed design of functional layout

Collecting infor#ation in functional layout

Collecting infor#ation in functional layout 6Continued7

;c< . 4 ,r, alternati*el# C + E

Collecting infor#ation in functional layout 6Continued7

GN-1 C,S1)+-S1ANCE 1RAIE%%E+

Collecting infor#ation in functional layout 6Continued7

;e< +A-%K C,S1)+-S1RANCE 1RAIE%%E+

Collecting infor#ation in functional layout 6Continued7

;.< +A-%K C,S1)+-S1RANCE 1RAIE%%E+

60 20 60 60 130 -. direction is not /00

Relatiel# robust in the case o. disru"tions Eas# to su"erise %o$ utili(ation

+isadantages Can hae *er# high 7-!

+isadantages Not er# robust in the case o.