Facility Layout

Facility Layout:
Manufacturing and Services
Slide 1 of 96
Introduction
• Facility layout means planning:
– for placing of machines, utilities, employee

workstations, customer service areas,
material storage areas, aisles, restrooms,
lunchrooms, internal walls, offices, and
computer rooms
– for the convenient flow patterns of materials

and people around, into, and within buildings
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Slide 2 of 96
Locate All Areas
• Equipment
• Work stations
• Material storage
• Rest/break areas
• Utilities
• Eating areas
• Aisles
• Offices
Slide 3 of 96
Major Objectives of an ideal layout
• Providing enough production capacity

• Reduction in materials Handling cost.
• Efficient and effective utilization of space
• Safe working conditions (accident free)
• Easy supervision
• Ease of maintenance – with high
machine/equipment utilization.
• Efficient labor utilization & increased
employee morale.
• Improvement in productivity
Slide 4 of 96
Factors influencing Layout
• Materials – the type of materials used / availability and

inventory policies, sizes of materials
• Product – whether heavy, light / big, small / liquid, solid
• Workers / operators – male /female
• Machinery – the type of product, volume, process,
size and type of machinery to be installed
• Type of Industry-whether batch processing / continuous
process etc.
• Location – size and terrain, type of building
• Managerial policies - make or buy decision / the extent
of automation / personal policies / purchasing policy
Slide 5 of 96
Criteria for a good Layout
– designing of a layout is a creative exercise
• Maximum Flexibility
• Maximum Co-ordination
• Maximum visibility
• Maximum Accessibility
• Minimum distance
• Minimum handling
• Minimum discomfort
• Inbuilt safety
• Efficient process flow
• Identification
Slide 6 of 96
Layout Type
Comparison
1. Speed
2. Flexibility
3. Type of machines / Capital cost
Slide 7 of 96
Various Types of Material Flows
Step 1 2 3 4 5 6
Straight Line
Cut Mill Weld Weld Grid Paint
U Shape L Shape
Sub assembly C
Sub assembly A
Sub assembly B
Serpentine
shape or
Convoluted
Slide
Main assembly line 8 of 96
Types of Layout
• Fixed position layout or Static layout
• Process layout or Functional layout
• Product layout or Flow–line layout
• Cellular manufacturing or group
technology layout
• Hybrid layout or Combination layout
• OFFICE LAYOUT
• RETAIL LAYOUT
Slide 9 of 96
Fixed-Position Layouts
 Typical of projects
 Job is Stationary,
 Eqpt., workers, materials,

other resources brought
to the Job site
 Highly skilled labor
Slide 10 of 96
Process Layout - Mfg.
Similar m/cs are located in process centers
Grinding Forging Lathes
Painting Welding Drills
Milling
Office machines Foundry
Slide 11 of 96
Process Layout - Hospital
Similar facilities are located in respective centers
E.R.Triag Patient A
- broken
e room
E.R.leg
Admissio ns
y
Patient B -
er
rg
erratic
Su
pacemaker
Hallway
Ra
di
ol
og
y
E.R. bedsPharmacy Billing/
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Slide 12 of 96
Process Layout in Retail
Women’s
Shoes Housewares
lingerie
Women’s Cosmetics Children’s

dresses and jewelry department
Women’s Entry and Men’s

sportswear display area department
Slide 13 of 96
Assy. Line ( Product Focused ) Layout
Product 1
Station 1 Station 2 Station 3 Station 4
Product 2
Station 1 Station Station 3 Station 4

2
Slide 14 of 96
Process Layout
Advantages :
• Reduced investment on m/cs – as they are general
purpose
• Production flexibility
• Maximum utilization of men and machines
• Easier maintenance
Disadvantages
• Difficulty in materials movement
• Layout requires more space
• Production time is more as WIP has to travel from point
to point in search of the machines
• Accumulation of WIP at different locations
Slide 15 of 96
Product Layout
Advantages
• Avoids production bottlenecks
• Economy in manufacturing time
• Requires less floor area per unit of production
• WIP reduced – consequently less inventories.
• Greater incentive to group of workers to raise their level
of production.
Disadvantages
• Layout is know for inflexibility
• Expensive layout
• Lesser scope for expansion
• M/c breakdown along the production line can disrupt the
whole system.
Slide 16 of 96
Group Technology
Dis-similar m/cs grouped to produced
SAME Family Products ( Gears) Machine
2
Machine
Machine 3
1
Materials in
Finished
goods out
Machine
Machine 4
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5 17
Slide 17 of 96
Cellular Manufacturing layout
Cell # 1 Cell # 2
1 2 3 Part D
1 2
3
Part X
5 4
Part Y
1 2
Part A 1 2
3
Part B 4 Cell # 4 Cell # 3
Slide 18 of 96
Cellular Manufacturing layout
• Machines are grouped into cells and the cells function
somewhat like a product layout within a larger process
layout.
• Each cell in this layout is formed to produce a single

family
• Lower WIP inventories, reduced materials handling

costs, simplified production planning
• Improved on time delivery
• Improved Quality.
Slide 19 of 96
Before : Process Layout
Jumbled flows in a job shop without GT
cells
Lathing Milling Drilling
L L D D
M M
D D
L L M M
Grinding
L L M M
G G
L L Assembly
G G
A A
Receiving and A A G G
shipping
Slide 20 of 96
After : Group Technology
L L M D G Assembly
area
Cell 1 Cell 2 A A
Receiving L M G G
Cell 3
L M D
Shipping
Slide 21 of 96
Hybrid Layout or Combined Layout
• A combination of the Product & Process

Layouts Product Layout
Raw F.P. G.C. G.G. Finished

H.T. Product
Materials
(Gears)
Raw H.T.
F.P. G.C. G.G.
Materials
G.C.
Process
layout
F.P. = Forging Press G.C. = Gear Cutting Machine 22

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H.T. = Heat Treatment Furnace G.G. = Gear Grinding machine
Slide 22 of 96
Service Facility Layout
Objectives are to maximize

– Customer satisfaction
– Utilization of space, equipment, & people
– Efficient flow of information, material, &
people
– Employee morale & safety
Slide 23 of 96
Computer Programs to Assist in Layout
• CRAFT
• SPACECRAFT
• CRAFT 3-D
• MULTIPLE
• CORELAP
• ALDEP
• COFAD
• FADES - expert system
Slide 24 of 96
Innovation at McDonald
• Indoor seating (1950’s)

• Drive-through window (1970s)
• Adding breakfast to the menu (1980s)
• Adding play areas (1990s)
(three out of the four are layout decisions)
Slide 25 of 96
McDonald’s - New Kitchen Layout
• 5th major innovation - kitchen design
– No food prepared ahead except patty
– Elimination of some steps, shortening of others
– New bun toasting machine (11 seconds vs 30 seconds)
– Repositioning condiment containers (1 motion, not 2)
– Sandwiches assembled in order
– Production levels controlled by computer
– Discard only meat when sandwiches do not sell fast
– Savings of $100,000,000 per year in food costs
Slide 26 of 96
Office Layout
• Design positions of people, equipment, & offices
for maximum information flow
• Arranged by process or product
– Example: Payroll dept. is by process
• Relationship chart used
• Examples
– Insurance company
– Software company
© 1995
Corel Corp. Slide 27 of 96
Office Layout Floor Plan
Accountin
Finance g
Fin. Acct.
Manager Brand X
Slide 28 of 96
Designing Retail Layouts
• Must be both attractive and functional
• 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
Slide 29 of 96
Types of Store Layouts
Slide 30 of 96
Retail Layouts - Some Rules of Thumb
• Design maximizes product exposure to customers

• Decision variables : Store flow pattern &
Allocation of (shelf) space to products
• Locate high-draw items around the periphery of the store
• Use prominent locations such as the first or last aisle for
high-impulse and high margin items
• Allow customers the opportunity to move between aisles
• Distribute “power items” (that may dominate a shopping
trip) to both sides of an aisle, and disperse them to
increase the viewing of other items
• Use end aisle locations because they have a very high
exposure rate ranesuhas@hotmail.com 31
Slide 31 of 96
Retail /Service Layout -
Grid Design
Grocery Store
Brea Meat
ce
Produ Frozen
d
Milk
Foods
Check
Office Cart
-
s
out
Slide 32 of 96
Store Layout - with Dairy, Bread, High
Drawer Items in Corners
Slide 33 of 96
Retail/Service Layout -
Free-Flow Design
Apparel Store
Feature Trans.
Counte
r
Display
Table
Slide 34 of 96
Retail Store - Shelf Space Planogram
• Computerized tool for 5

shelf-space facings
PERT
PERT
PERT
PERT
PERT
management
• Generated from
store’s scanner data
SUAVE
SUAVE
on sales
VO-5
VO-5
VO-5
VO-5
VO-5
• Often supplied by
manufacturer
– Example: P&G 2 ft.
Slide 35 of 96
Parts Families
A family of A family of related

similar parts grocery items
Slide 36 of 96
New Trends in Manufacturing Layouts
● Designed for quality and flexibility

● Simultaneous – Product Flexibility & Volume Flex.
● Cellular layout within larger process layouts
● Automated material handling
● U-shaped production lines
● More open work areas, fewer partitions/ obstacles
● Smaller and more compact factory layouts
● Less space for inv. storage throughout the layout
Slide 37 of 96
Flexible Manufacturing Systems
(FMS)
• FMS consists of numerous programmable machine tools
connected by an automated material handling system
and controlled by a common computer network
• FMS combines flexibility with efficiency
• FMS layouts differ based on
– variety of parts that the system can process
– size of parts processed
– average processing time required for part completion
Slide 38 of 96
Full-Blown FMS
Slide 39 of 96
Line Balancing Problem
● Work stations are arranged so that the output of one is

an input to the next, i.e., a series connection
● Layout design involves assigning one or more of the

tasks required to make a product to work stations
● . . . more
Slide 40 of 96
Line Balancing Problem
● Objective : to assign tasks to minimize the workers’ idle time

costs, and meet the reqd. production rate.
● In a perfectly balanced line, all workers would complete their

assigned tasks at the same time
● Conditions preventing Perfectly balanced line

●
The estimated times for tasks
●
The precedence relationships for the tasks
●
The combinatorial nature of the problem
Slide 41 of 96
How Good Is the Design?
● Utilization is the percentage of time that a production

line is working.
● Utilization is calculated as:

Theoritical No. of workstations
x100
Actual number of workstations
or
Sum of all task times
x 100
(Cycle Time) x (Actual number of work stations)
Slide 42 of 96
Product Layouts-Major Assumptions
● Volume is adequate for high equipment utilization.

● Product demand is stable.
● Product is standardized
● Supplies of raw material and components are
adequate and of uniform quality.
Slide 43 of 96
Why is Balancing the Line Important?
Station 1 Station 2 Station 3

Min/
Unit 6 7 3
What’s Going to Happen?
Slide 44 of 96
Example 1: The ALB Problem
● You’ve just been assigned the job a setting up an electric fan
assembly line with the following tasks:
Task Time (Mins) Description Predecessors

A 2 Assemble frame None
B 1 Mount switch A
C 3.25 Assemble motor housing None
D 1.2 Mount motor housing in frame A, C
E 0.5 Attach blade D
F 1 Assemble and attach safety grill E
G 1 Attach cord B
H 1.4 Test F, G
2 1 1
A B G 1.4
H
C D E F
3.25 1.2 .5 1 Slide 45 of 96
The Bottleneck
Production time per day 420 mins

Max Production = = = 129 units
Bottleneck time 3.25 mins / unit
Task Time (Mins) Description Predecessors

A 2 Assemble frame None
B 1 Mount switch A
C 3.25 Assemble motor housing None
D 1.2 Mount motor housing in frame A, C
E 0.5 Attach blade D
F 1 Assemble and attach safety grill E
G 1 Attach cord B
H 1.4 Test E, G
Slide 46 of 96
We want to assemble 100 fans per day
Production time per period

Required Cycle Time, C =
Required output per period
420 mins / day

C= = 4.2 mins / unit
100 units / day
What do these numbers this represent?
Slide 47 of 96
We want to assemble 100 fans per day
Theoretical Min. Number of Workstations, N t
Sum of task times (T)

Nt =
Cycle time (C)
11.35 mins / unit

Nt = = 2.702, or 3
4.2 mins / unit
Why should we always round up?
Slide 48 of 96
Selected Task Selection Rules
● Primary: Assign tasks in order the the largest number

of following tasks.
● Secondary (tie-breaking): Assign tasks in order of the

longest operating time
Slide 49 of 96
Task Followers Time (Min)
A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
E 2 0.5
C D E F
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4
Slide 50 of 96
A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
E 2 0.5
C D E F
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4
A (4.2-2=2.2)
Slide 51 of 96
A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
E 2 0.5
C D E F
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4
A (4.2-2=2.2)
B (2.2-1=1.2)
Slide 52 of 96
A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
E 2 0.5
C D E F
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4
A (4.2-2=2.2)
B (2.2-1=1.2)
G (1.2-1= .2)
Idle= .2
Slide 53 of 96
A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
E 2 0.5
C D E F
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4
A (4.2-2=2.2) C (4.2-3.25)=.95
B (2.2-1=1.2)
G (1.2-1= .2)
Idle= .2 Idle = .95
Slide 54 of 96
A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
E 2 0.5
C D E F
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4
A (4.2-2=2.2) C (4.2-3.25)=.95 D (4.2-1.2)=3

B (2.2-1=1.2)
G (1.2-1= .2)
Idle= .2 Idle = .95
Slide 55 of 96
A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
E 2 0.5
C D E F
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4
A (4.2-2=2.2) C (4.2-3.25)=.95 D (4.2-1.2)=3

B (2.2-1=1.2) E (3-.5)=2.5
G (1.2-1= .2)
Idle= .2 Idle = .95
Slide 56 of 96
A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
E 2 0.5
C D E F
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4
A (4.2-2=2.2) C (4.2-3.25)=.95 D (4.2-1.2)=3

B (2.2-1=1.2) E (3-.5)=2.5
G (1.2-1= .2) F (2.5-1)=1.5
Idle= .2 Idle = .95
Slide 57 of 96
A 6 2
2 1 1
1.4 C 4 3.25
A B G
H D 3 1.2
B 2 1
E 2 0.5
C D E F
F 1 1
3.25 1.2 .5 1
G 1 1
H 0 1.4

C (4.2-3.25)=.95 D (4.2-1.2)=3
A (4.2-2=2.2)
E (3-.5)=2.5
B (2.2-1=1.2)
F (2.5-1)=1.5
G (1.2-1= .2)
H (1.5-1.4)=.1
Idle=.2 Idle=.95 Idle=.1

Slide 58 of 96
• Which station is the bottleneck?

• What is the effective cycle time?
Sum of task times (T)

Efficiency =
Actual number of workstations (Na) x Cycle time (C)
11.35 mins / unit

Efficiency = =.901
(3)(4.2mins / unit)
Slide 59 of 96
Wrap-Up: World-Class Practice
●
Strive for flexibility in layouts
●
Multi-job training of workers
●
Sophisticated preventive-maintenance programs
●
Flexible machines
●
Empowered workers trained in problem solving
●
Layouts small and compact
Slide 60 of 96

Facility Layout

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Facility Layout:

Manufacturing and Services

• Facility layout means planning:

– for placing of machines, utilities, employee

– for the convenient flow patterns of materials

• Providing enough production capacity

• Materials – the type of materials used / availability and

 Eqpt., workers, materials,

 Highly skilled labor

Grinding Forging Lathes

Painting Welding Drills

Women’s Cosmetics Children’s

Women’s Entry and Men’s

Station 1 Station 2 Station 3 Station 4

Station 1 Station Station 3 Station 4

Part B 4 Cell # 4 Cell # 3

• Each cell in this layout is formed to produce a single

• Lower WIP inventories, reduced materials handling

• Improved on time delivery

• A combination of the Product & Process

Raw F.P. G.C. G.G. Finished

F.P. = Forging Press G.C. = Gear Cutting Machine 22

Objectives are to maximize

• Indoor seating (1950’s)

(three out of the four are layout decisions)

– Loop and Spine layouts

• Design maximizes product exposure to customers

• Computerized tool for 5

A family of A family of related

● Designed for quality and flexibility

● Work stations are arranged so that the output of one is

● Layout design involves assigning one or more of the

● Objective : to assign tasks to minimize the workers’ idle time

● In a perfectly balanced line, all workers would complete their

● Conditions preventing Perfectly balanced line

● Utilization is the percentage of time that a production

● Utilization is calculated as:

● Volume is adequate for high equipment utilization.

Station 1 Station 2 Station 3

What’s Going to Happen?

Task Time (Mins) Description Predecessors

Production time per day 420 mins

Task Time (Mins) Description Predecessors

Production time per period

420 mins / day

What do these numbers this represent?

Theoretical Min. Number of Workstations, N t

Sum of task times (T)

11.35 mins / unit

Why should we always round up?

● Primary: Assign tasks in order the the largest number

● Secondary (tie-breaking): Assign tasks in order of the

Station 1 Station 2 Station 3

Station 1 Station 2 Station 3

Station 1 Station 2 Station 3

Station 1 Station 2 Station 3

Station 1 Station 2 Station 3

Idle= .2 Idle = .95

Station 1 Station 2 Station 3

A (4.2-2=2.2) C (4.2-3.25)=.95 D (4.2-1.2)=3

Idle= .2 Idle = .95

Station 1 Station 2 Station 3