FACILITY LAYOUT & LOCATION PROF. DR. ORHAN TORKUL M. RAŞİT CESUR

Objectives Be able to define activity relationship chart and its function Be able to identify relationship codes Be able to construct an activity relationship chart Be able to construct a dimensionless block diagram Be able to utilize the block diagram to analyze flow

Activity Relationship Diagram The activity relationship diagram, also called an affinity analysis diagram, shows the relationship of every department, office, or service area with every other department and area. It answers the question, How important is it for this department, office, or service facility to be close to another department, office, or service facility? This question needs to be asked about the relationship of every department, office, or service facility with every other department, office, or service facility.

Activity Relationship Diagram Closeness codes are used to reflect the importance of each relationship. The codes are given as follows; CodeDefinition AAbsolutely necessary that these two departments be next to each other EEspecially important IImportant OOrdinary importance UUnimportant XCloseness undesirable

Activity Relationship Diagram The A code should be restricted to the movement of massive amounts of material between departments The need for great numbers of people moving could also be classified as A codes; for example, maintenance and the tool and supplies crib are an A code. Sometimes you can combine two departments, offices, or service facilities together. Maintenance and the toolroom, and the restroom and lockers, are other examples of departments and service facilities, respectively, that should not be divided.

Activity Relationship Diagram Use E codes if there is any doubt that it is an A code. Much material or many people move between these two departments, but not everything or everyone moves all the time. For example, everyone needs the restroom, or break room, but not all the time. Departments with few people may have the same needs, but because of the fewer people, there is less need to place them close to the services. Use I and O codes when some level of importance is desired, but these closeness codes are not as useful as the others. It is not a good idea to omit these codes, at least for the first few layout designs.

Activity Relationship Diagram U codes are useful because they tell you when no activity or interface is needed between two departments. These departments can be placed far away from each other. X codes are as important as A codes, but for the opposite reason. For example, if the paint department is located next to the welding department, an explosion is possible. Noise, smell, heat, dust, cold, and so on are all good reasons for an X code.

Activity Relationship Diagram

Here is a step-by-step procedure for developing an activity relationship diagram: List all departments in a vertical column on the left-hand side of the form. Starting with line 1 (fabrication), establish the relationship code for each following department. Establishing these relationship codes requires an understanding of all the departments, an understanding of management attitudes, and a determination to produce the most efficient layout possible. Reason codes can be used like asterisks. For example, you do not want shipping and receiving close to each other. Why? A 1 could be placed below the X in the 5-8 intersection below the activity relationship code.

Activity Relationship Diagram You would write a reason code key below the diagram: Reason code can be written in activity relationship diagram as given below; Reason CodeReason 1For better flow 2All material moves between these two departments 3People movement and so on

Determining the Relationship Code The relationship or affinity codes state the desired degree of closeness between two activity centers. Each code can be broken down into a qualitative and a quantitative component in order to facilitate the assignment of the codes. The quantitative component of the relationship between two departments or work centers can be based on the actual flow of material.

Determining the Relationship Code Considerations given to how many parts per day, or how many different parts, or how many tons of material are moved between the two given work centers can be a great aid in determining the proper relationship codes between the two centers. Flow lines can be drawn between the two activity codes to depict the movement of the parts or people. The number of lines or the intensity of the flow will then indicate the desired degree of closeness.

Determining the Relationship Code One numbering or weighing scheme may assign arbitrary values to the relationship codes as follows: A = 4, E = 3, I = 2, and O = 1. Using the same scale, one can evaluate the intensity of the flow lines between the centers. The qualitative component in assigning relationship codes can be based on expert opinions and the judgment of individuals as to where two departments or centers should be located in relation to each other and in assigning a relative number to the relationship.

Determining the Relationship Code A rule-of-thumb approach states that you should not exceed the following percentages for a given code: CodePercentage A5 E10 I15 O25

Determining the Relationship Code The remaining relationships will probably be assigned as U, with the exception, of course, of where a code X is deemed necessary. The total number of relationships, N, between all possible pairs of work centers in any facility can be determined as follows: N= For example, for a facility with 25 different departments or work centers, N= = 300 n(n-1) 2 25(25-1) 2

Determining the Relationship Code Using the rule of thumb described above, the facilities planner in this case should have no more than 15 A relationship codes (300 × 5 percent = 15). Similarly, it is reasonable to expect that the number of E and I codes should not exceed 30 and 45, respectively.

Dimensionless Block Diagram The dimensionless block diagram is the first layout attempt and the result of the activity relationship chart and the worksheet. Even though this layout is dimensionless, it will be the basis for the master layout and plot plan. Once the size of every department, office, and support facility has been determined, space will be allocated to each activity per the dimensionless block diagram’s layout. Sometimes it is harder laying out the dimensionless block diagram than when exact sizes are available, because large departments tend to have more A and E relationships than small departments and can have many more departments (activities) on its borders.

Dimensionless Block Diagram Here’s a step-by-step procedure for a dimensionless block diagram; Cut up a sheet of paper into about 2 × 2-inch squares. (In this example, 14 squares are needed.) Place an activity number in the center of each square (1 to 14 in this example). Taking one square at a time, make a template for that activity by placing the relationship codes in the following positions: A relationship in the top left corner E relationship in the top right corner I relationship in the bottom left corner O relationships in the bottom right corner U relationships omitted X relationships in the center under the activity number

Dimensionless Block Diagram Here’s a step-by-step procedure for a dimensionless block diagram; Each activity center is represented by one square. Once the 14 templates are ready, you place them in the arrangement that will satisfy as many activity codes as possible.

Activity Relationship Worksheet

Dimensionless Block Diagram

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