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To Accompany Russell and Taylor, Operations Management, 4th Edition, 2003 Prentice-Hall, Inc. All rights reserv To Accompany Russell and Taylor, Operations Management, 4th Edition, 2003 Prentice-Hall, Inc. All rights re
To Accompany Russell and Taylor, Operations Management, 4th Edition, 2003 Prentice-Hall, Inc. All rights reserv
To Accompany Russell and Taylor, Operations Management, 4th Edition, 2003 Prentice-Hall, Inc. All rights reserv
To Accompany Russell and Taylor, Operations Management, 4th Edition, 2003 Prentice-Hall, Inc. All rights reserv
Usually the layout is planned to minimize a particular criterion: For example, minimizing total traveling time, total cost, total delays, etc. There are also situations in which the layout may be designed to maximize a criterion: For example, maximize quality, flexibility, or space utilization.
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Product Layout
Linear arrangement of workstations to produce a specific product
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Womens dresses
Childrens department
Womens sportswear
Mens department
Figure 5.1
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L L L L L
L L L L L
M M G G
M M G G
Grinding Department Receiving and Shipping
D D G G
D D P P
D D
D D
Painting Department
A
Assembly
Figure 5.2
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L L L L L
L L L L L
M M G G
M M G G
Grinding Department Receiving and Shipping
D D G G
D D P P
D D
D D
Painting Department
A
Assembly
Figure 5.2
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L L L L L
L L L L L
M M G G
M M G G
Grinding Department Receiving and Shipping
D D G G
D D P P
D D
D D
Painting Department
A
Assembly
Figure 5.2
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A Product Layout
Specialized equipment High capital intensity & wide use of automation Processing rates are faster Material handling costs are lower Less space required for inventories Less volume or design flexibility
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A Product Layout
In
Out
Figure 5.3
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Table 5.1
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Fixed-Position Layouts
Typical of projects Equipment, workers, materials, other resources brought to the site Highly skilled labor Often low fixed Typically high variable costs
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Relationship Diagramming
Based on location preference between areas Use when quantitative data is not available
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Block Diagramming
Create load summary chart Calculate composite (two way) movements Develop trial layouts minimizing number of nonadjacent loads
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Process Layout
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Example 5.1
Process Layout
Load Summary Chart
FROM/TO DEPARTMENT
Department 1 1 2 3 4 5 60
2 100 100 50
3 50 200
4 50 40
50 60
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Example 5.1
Process Layout
Load Summary Chart
FROM/TO DEPARTMENT
Department 1
Composite 23 24 13 12 45
1 100 50 2 200 50 3 60 40 50 4 100 60 Movements Composite Movements 5 50 200 loads 35 50 loads 150 loads 25 50 loads 110 loads 34 40 loads 100 loads 14 0 loads 60 loads 15 0 loads
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Example 5.1
Process Layout
Load Summary Chart
FROM/TO DEPARTMENT 1
2 5
Department 1
Composite 23 24 13 12 45
1 100 50 2 4 200 50 5 3 60 40 50 4 100 60 Movements Composite Movements 5 50 200 loads 35 50 loads 150 loads 25 50 loads 110 loads 34 40 loads 100 loads 14 0 loads 60 loads 15 0 loads
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Example 5.1
Process Layout
110
200
Department 1
3150
50
5 50
Composite 23 24 13 12 45
1 100 50 60 2 4 200 50 5 3 60 40 50 4 100 1 60 40 Grid Movements Composite Movements 5 50 200 loads 35 50 loads 150 loads 25 50 loads 110 loads 34 40 loads 100 loads 14 0 loads 60 loads 15 0 loads
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Example 5.1
Process Layout
Load Summary Chart
FROM/TO 100 DEPARTMENT 1
150
4
40 60
Department 1
3
110
4 200
5 50
Composite 23 24 13 12 45
1 100 50 50 5 2 200 50 3 3 60 40 50 4 100 2 60 Grid Movements Composite Movements 5 50 200 loads 35 50 loads 150 loads 25 50 loads 110 loads 34 40 loads 100 loads 14 0 loads 60 loads 15 0 loads
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Block Diagrams
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Block Diagrams
(a) Initial block diagram
Figure 5.4
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Block Diagrams
(a) Initial block diagram (b) Final block diagram
Figure 5.4
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Relationship Diagramming
Used when quantitative data is not available Muthers grid displays preferences Denote location preferences with weighted lines
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O U A U O
A O U O
I X O
E U
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O U A U O
A O U O
I X O
E U
Figure 5.5
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Relationship Diagrams
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Relationship Diagrams
(a) Relationship diagram of original layout
Offices
Locker room
Stockroom
Toolroom
Figure 5.6
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Relationship Diagrams
(b) Relationship diagram of revised layout
Stockroom Shipping and receiving
Offices
Toolroom
Production
Locker room
Figure 5.6
Key: A E I O U X
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Service Layouts
Usually process layouts due to customers needs Minimize flow of customers or paperwork Retailing tries to maximize customer exposure to products Computer programs consider shelf space, demand, profitability Layouts must be aesthetically pleasing
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Line Balancing
Precedence diagram
Network showing order of tasks and restrictions on their performance
Cycle time
Maximum time product spends at any one workstation
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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 =
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2
4 minutes
3
4 minutes
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Efficiency of Line
Efficiency Minimum number of workstations
E = nC a
where
t
i=1
N=
t
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
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Line Balancing
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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
Example 5.2
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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
B
0.1
0.2
A C
0.4
D 0.3
Example 5.2
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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
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 C 0.4 0.4 Example 5.2
0.2
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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
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 3 C 0.4 0.4 Example 5.2 workstations
0.2
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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 Cd = 0.4 N = 2.5
B
0.1
0.2
A C
0.4
D 0.3
Example 5.2
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Line Balancing
WORKSTATION ELEMENT REMAINING TIME REMAINING ELEMENTS
B
0.1
0.2
Cd = 0.4 N = 2.5
A C
0.4
D 0.3
Example 5.2
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Line Balancing
WORKSTATION 1 ELEMENT A REMAINING TIME 0.3 REMAINING ELEMENTS B, C
B
0.1
0.2
Cd = 0.4 N = 2.5
A C
0.4
D 0.3
Example 5.2
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Line Balancing
WORKSTATION 1 ELEMENT A B REMAINING TIME 0.3 0.1 REMAINING ELEMENTS B, C C, D
B
0.1
0.2
Cd = 0.4 N = 2.5
A C
0.4
D 0.3
Example 5.2
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Line Balancing
WORKSTATION 1 2 ELEMENT A B C REMAINING TIME 0.3 0.1 0.0 REMAINING ELEMENTS B, C C, D D
B
0.1
0.2
Cd = 0.4 N = 2.5
A C
0.4
D 0.3
Example 5.2
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Line Balancing
WORKSTATION 1 2 3 ELEMENT A B C D 0.2 REMAINING TIME 0.3 0.1 0.0 0.1 REMAINING ELEMENTS B, C C, D D none Cd = 0.4 N = 2.5
B
0.1
A C
0.4
D 0.3
Example 5.2
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Line Balancing
WORKSTATION 1 2 3
Work ELEMENT station 1
A B A, B C 0.3 D minute
REMAINING
B
0.1
0.2
A C
0.4
D 0.3
Example 5.2
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Line Balancing
WORKSTATION 1 2 3
Work ELEMENT station 1
A B A, B C 0.3 D minute
REMAINING
B
E=
0.2
1.0 0.1 + 0.2 + 0.3 + 0.4 0.1 A = = 0.833 = 83.3% D 0.3 1.2 3(0.4)
Example 5.2
0.4
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Hybrid Layouts
Cellular layouts
Group machines into machining cells
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Cellular Layouts
1. Identify families of parts with similar flow paths 2. Group machines into cells based on part families 3. Arrange cells so material movement is minimized 4. Locate large shared machines at point of use
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Parts Families
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A
Figure 5.8
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1 x
2 x
Machines 4 5 6 7 x x x x x x x x
8 9 10 11 12 x x x x x x x x x
x x x x x
x x
x x
x x
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A B C Raw materials
Figure 5.9
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1 x x x
2 x x
4 x x x
Machines 8 10 3 6 x x x x x x x x x
9 5
7 11 12
x x x x x x x
x x x x
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FMS Layouts
Figure 5.12
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FMS Layouts
Figure 5.12
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Figure 5.13
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9 min Efficiency =
12 min
3 min
Figure 5.13
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9 min Efficiency =
12 min
3 min
C,D
Figure 5.13
Efficiency =
12 min
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