1 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Facilities Layout

2 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Basic Layout Types u Product Layouts u Process Layouts u Fixed-Position u Combination Layouts

3 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Basic Layout Formats u Group Technology Layout u Just-in-Time Layouts –May be assembly-line or –Group Technology formats u Fixed Position Layout –e.g. Shipbuilding

4 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 The Need for Layout Decisions Inefficient operations For Example: High Cost Bottlenecks Changes in the design of products or services The introduction of new products or services Accidents Safety hazards

5 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 The Need for Layout Designs (Cont’d) Changes in environmental or other legal requirements Changes in volume of output or mix of products Changes in methods and equipment Morale problems

6 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Cellular Layouts u Cellular Manufacturing u Group Technology u Flexible Manufacturing Systems

7 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Basic Layout Types u Product Layout (classify by nature of product) –Layout that uses standardized processing operations to achieve smooth, rapid, high-volume flow u Process Layout (classify by nature of process) –Layout that can handle varied processing requirements u Fixed Position Layout –Layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed

8 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 A Flow Line for Production or Service Flow Shop or Assembly Line Work Flow Raw materials or customer Finished item Station 2 Station 3 Station 4 Material and/or labor Station 1 Material and/or labor Material and/or labor Material and/or labor

9 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 A U-Shaped Production Line In Out Workers

10 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Process Layout Milling Assembly & Test Grinding Drilling Plating Process Layout - work travels to dedicated process centers

11 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Cellular Layouts u Cellular Manufacturing –Layout in which machines are grouped into a cell that can process items that have similar processing requirements u Group Technology –The grouping into part families of items with similar design or manufacturing characteristics

12 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Cellular Manufacturing Layout Assembly Lathe Mill Drill Heat treat Heat treat Heat treat Gear cut Gear cut Grind

13 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Design Product Layouts: Line Balancing Line Balancing is the process of assigning tasks to workstations in such a way that the workstations have approximately equal time requirements.

14 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Cycle Time Cycle time is the maximum time allowed at each workstation to complete its set of tasks on a unit.

15 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Determine Maximum Output

16 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Determine the number of workstations u The minimum No. of workstations required = Daily demand  total time to finish a unit Total operating time in one day (per workstation)

17 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Determine the Minimum Number of Workstations Required: Efficiency

18 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Rules to solve line-balancing problem u Can be formulated as integer programming problems. The following simple heuristics (intuitive rules) are used for simple problems 1. Assign tasks in order of most following tasks 2. Assign tasks in order of greatest positional weight. Posistional weight is the sum of each task’s time and the times of all following tasks.

19 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Precedence Diagram Precedence diagram: Tool used in line balancing to display elemental tasks and sequence requirements A Simple Precedence Diagram a b cd e 0.1 min. 0.7 min. 1.0 min. 0.5 min.0.2 min.

20 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Example 1: Assembly Line Balancing u Arrange tasks shown in the previous slide into workstations. –Use a cycle time of 1.0 minute –Assign tasks in order of the most number of followers

21 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Solution to Example 1

22 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Calculate Percent Idle Time

23 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Example 1 u Percentage of idle time = 0.5 / (3 1.0) = 16.7% u Efficiency = 100% % = 83.3%

24 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Solution to Example 2 Station 1Station 2Station 3Station 4 ab e f d g h c

25 IRWIN  a Times Mirror Higher Education Group, Inc. company, 1996 Interdepartmental Work Flows for Assigned Departments ABC