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Dr. J. R. SHARMA
@IMT, NAGPUR
Outline
Basic Layouts
Categories of Layouts
Designing Product Layouts
Designing Process Layouts
Hybrid Layouts
FACILITIES
Facility Layout refers to the arrangement / placement of
resources within an existing or proposed facility.
Facilities must be planned, located and then laid out.
Facilities decision affects workers efficiency, rate of
production, quality of production, level of automation, and how
responsive is the system to changes in product design
Basic objective of the layout decision is to ensure smooth flow
of work, material, people and information through the system or
a particular traffic pattern in case of a service orgn.
Provides competitive edge by enabling and leveraging the latest
process concepts.
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Facility Layout
Arrangement of areas within a facility to:
Facility Layout
Eliminate 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
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BASIC LAYOUTS
Process layouts
Functional layout / Job shop / Flexible
Group similar activities together according to process they perform
Product layouts
Assembly lines or Flow lines / Efficient
Arrange activities in line according to sequence of operations
Fixed-position layouts
Projects like house, ship or aircraft building, etc.
Are used for projects in which product cannot be moved
Equipments and other things are moved, not the product
Hybrid layouts
Shoes
House-wares
Womens dresses
Cosmetics and
jewelry
Childrens
department
Sportswear
Mens
department
Milling
Department
Drilling Department
Grinding
Department
Receiving and
Shipping
Painting Department
Assembly
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Product Layout
In
Out
Tc =
Tc =
Tc =
480
120
= 4 minutes
12
3 minutes
4 minutes
3 minutes
Efficiency of Line
Efficiency
j
t
i=1
E = n*T
c
Minimum number
of workstations
j
i=1
Min. N = T
c
where
ti
j
N
Tc
C,D
9 min
12 min
3 min
Efficiency =
24
24
=
= .6666 = 66.7 %
3(12)
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C,D
Efficiency =
24
24
=
= 100 % 12 min
2(12)
24
12 min
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The table below defines the precedence relationships and element times for a
new model toy. (a) Construct the precedence diagram for this job. (b) If the ideal
cycle time = 1.0, what is the theoretical minimum number of workstations
required to minimize the balance delay (c) Assign work elements to stations. (d)
Compute the balance delay for your solution.
Work element
Te (minute)
Immediate predecessors
1
2
3
4
5
6
7
8
9
10
0.5
0.3
0.8
0.2
0.1
0.6
0.4
0.5
0.3
0.6
1
1
2
2
3
4,5
3,5
7,8
6,9
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Time Te
Element
Time Te
0.4 min.
Preceded
by:
-
0.2 min.
Preceded
by:
3
1
2
0.7 min.
0.3 min.
0.5 min.
0.9 min.
5,6
0.8 min.
0.8 min.
7,8
1.0 min.
2, 3
10
0.5 min.
6,9
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Relationship Diagramming:
A
E
I
O
U
X
Absolutely necessary
Especially important
Important
Okay
Unimportant
Undesirable
Production
O
A
Offices
Stockroom
Shipping and
receiving
X
U
O
O
Locker room
O
Toolroom
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Offices
Stockroom
Locker
room
Toolroom
Shipping
and
receiving
Production
Key: A
E
I
O
U
X
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Stockroom
Shipping
and
receiving
Offices
Toolroom
Production
Locker
room
Key: A
E
I
O
U
X
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Hybrid Layouts
Parts Families
A family of
similar parts
A family of related
grocery items
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Are concerned with - circulation of traffic through the facility; minimizing flow of
paper work; maximize customer exposure to as many goods as possible
Back office (invisible) for efficiency and functionality and front office (full view of
the customers) for its aesthetics and functionality
Types:
Free flow layouts - encourage browsing, increase impulse purchasing, are flexible
and visually appealing
Grid layouts - encourage customer familiarity, are low cost, easy to clean and secure,
and good for repeat customers
Loop and Spine layouts - both increase customer sightlines and exposure to
products, while encouraging customer to circulate through the entire store
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THANK YOU
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