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Describe four layout patterns and when they should be used Explain how to design product layouts using assembly line balancing Explain the concepts of process layout Describe issues related to workplace design Describe the human issues related to workplace design

Specific arrangement of physical facilities Facility Layout Specific arrangement of physical facilities Layout studies are necessary whenever: New facility is constructed Significant change in demand or throughput volume New good or service is introduced to the customer benefit package Different processes, equipment, and/or technology are installed

Objectives of Layout Studies Minimize delays in materials handling and customer movement Maintain flexibility Use labor and space effectively Promote high employee morale and customer satisfaction

Objectives of Layout Studies Provide for good housekeeping and maintenance Minimize energy use and environmental impact Enhance sales as appropriate in manufacturing and service facilities

Types of Layout Patterns Product layout Process layout Cellular layout Fixed-position layout

Product Layout Arrangement based on the sequence of operations that is performed during manufacturing of a good or delivery of a service Supports a smooth and logical flow where goods or services move in a continuous path from one process stage to next, using the same sequence of work tasks and activities

Product Layout Advantages Disadvantages Higher output rates Lower work-in-process inventories Less material handling Higher labor and equipment utilization Simple planning and control systems Disadvantages Breakdown at one workstation can cause the entire process to shut down Change in product design or the introduction of new products can require major changes in the layout Limited flexibility

8.1 Product Layout for a Wine Manufacturer

Functional grouping of equipment or activities that do similar work Process Layout Functional grouping of equipment or activities that do similar work Compared with product layouts Provide flexibility Require lower investment in equipment

Process Layout Disadvantages Advantages Low equipment utilization High material handling costs More complicated planning and control systems Higher worker skill requirements Advantages Lower investment in equipment Diversity of jobs inherent in a process layout can lead to increased worker satisfaction

8.2 Process Layout for a Machine Shop

Cellular Layout Self-contained groups of equipment needed for producing a particular set of goods or services Design is not according to the functional characteristics of equipment

Advantages of Cellular Layout Reduced materials-handling requirements Quicker response to quality problems More efficient use of floor space More worker responsibility increasing morale

8.3 Cellular Manufacturing Layout

Fixed-position Layout Consolidates the necessary resources in one physical location to manufacture a good or deliver a service Advantage Work remains stationary Disadvantage High level of planning and control required

8.4 Comparison of Basic Layout Patterns

Facility Layout in Service Organizations Service organizations use product, process, cellular, and fixed-position layouts to organize different types of work Basic trade-off between product and process layouts concerns the degree of specialization versus flexibility Service organizations that provide highly standardized services tend to use product layouts

8.5 Product Layout for a Pizza Kitchen

Designing Product Layouts Product layouts in flow shops consist of a fixed sequence of workstations separated by buffers Suffer from sources of delay such as: Flow-blocking: Occurs when work center completes a unit but cannot release it because the in-process storage at the next stage is full Worker remains idle until storage space becomes available

Designing Product Layouts Lack-of-work: Occurs when one stage completes work and no units from the previous stage are awaiting processing Type Assembly line: Combining the components of a good or service that has been created previously

Assembly-Line Balancing Technique to group tasks among workstations Each workstation has the same amount of work Types of information Set of tasks to be performed and the time required to perform each task Precedence relations among the tasks Desired output rate or forecast of demand for the assembly line

8.6 A Typical Manufacturing Workstation Layout

Interval between successive outputs coming off the assembly line Cycle Time Interval between successive outputs coming off the assembly line Cycle time (CT) is related to the output (R) by the following equation CT = A/R A - Available time to produce the output Output (R) - Demand forecast in units, adjusted for on-hand inventory, or orders released to the factory Both A and R must have the same time units of measure

Cycle Time If the required cycle time is smaller than the larger task time Then, the work content must be redefined by splitting some tasks into smaller elements Minimum number of workstations required = Sum of task times/Cycle time = Σt/CT

Cycle Time Total time available = (Number of work stations)×(Cycle Time) = (N)(CT) Total idle time = (N)(CT) - Σt Assembly-line efficiency = Σt/(N ×CT) Balance delay = 1 - Assembly-line efficiency

Line-Balancing Approaches Use decision rules, or heuristics, to assign tasks to workstations To attempt to minimize the amount of idle time at workstations Do not guarantee optimal solutions

8.7 A Three-Task Assembly Line

8.9 Precedence Network and Workstation Assignment

Designing Process Layouts Arrangement of departments or work centers relative to each other Approaches Focuses on the cost associated with moving materials Used when it is difficult to obtain data on costs or volumes moved between departments

Workplace Design Well-designed workplace allows for maximum efficiency and effectiveness as the work task or activity is performed Needs to facilitate service management skills in high-contact, front-office environments

8.10 Pizza Preparation Workplace Design

Safety and the Work Environment Function of the job - Designed in a way where the worker can’t get injured Person performing the job - Educated in the proper use of equipment Surrounding environment Non slip surfaces Warning signs, or buzzers

Ergonomics Concerned with improving productivity and safety and taking into account the physical capabilities of people by designing: Workplaces Equipment Instruments Computers Workstations

Job: Set of tasks an individual performs The Human Side of Work Job: Set of tasks an individual performs Job design involves: Determining the specific job tasks and responsibilities Work environment Methods by which the tasks will be carried out to meet the goals of operations Job enlargement: Horizontal expansion of the job to give the worker more variety

The Human Side of Work Job enrichment: Vertical expansion of job duties to give the worker more responsibility Highly effective approach to job enrichment is to use teams Natural work teams Virtual teams Self-managed teams (SMTs)

Types of layout patterns Product Process Cellular Fixed-position Interval between successive outputs coming off the assembly line is cycle time Safety is required in aspects of function of job, person performing the job and the environment

Assembly line Assembly-line balancing Cellular layout Cycle time Ergonomics Facility layout Fixed-position layout Flow-blocking delay

Job Job design Job enlargement Job enrichment Lack-of-work delay Process layout Product layout