Facility Layout Part a

Definition (J. M. Apple) Arrangement of physical facilities to optimize the interrelationships among operating personnel, material flow, information flow, and the methods required in achieving enterprise objectives efficiently, economically, and safely.

The Overall Objective of Facility Layout To get the inputs (materials, supplies, etc.) into, through, and out of each facility in the shortest practicable time, at an acceptable cost.

Objectives of Facility Layout Minimize material handling costs Utilize space efficiently Utilize labor efficiently Eliminate bottlenecks Facilitate communication and interaction between workers, between workers and their supervisors, or between workers and customers Minimize investment in equipment

Reduce manufacturing cycle time or customer service time Eliminate waste or redundant movement Facilitate the entry, exit, and placement of material, products, or people Incorporate safety and security measures Promote product and service quality Encourage proper maintenance activities Provide a visual control of operations or activities Provide flexibility to adapt to changing conditions Provide for employee convenience, safety, and comfort

Basic Types of Layouts Process Layout (or Lot Production) machines grouped by process they perform Product Layout (or Continuous Production) linear arrangement of workstations to produce a specific product Fixed Position Layout used in projects where the product cannot be moved

Hybrid Layouts Cellular layouts Flexible manufacturing systems group machines into machining cells Flexible manufacturing systems automated machining & material handling systems Mixed-model assembly lines produce variety of models on one line

Manufacturing Process Layout D G A Receiving and Shipping Assembly Painting Department Lathe Department Milling Department Drilling Department Grinding P

Service Process Layout Women’s lingerie Women’s dresses Women’s sportswear Shoes Cosmetics and jewelry Entry and display area Housewares Children’s department Men’s department

A Product Layout In Out

Comparison Of Product And Process Layouts PRODUCT LAYOUT PROCESS LAYOUT 1. Description Sequential arrangement Functional grouping of machines of machines 2. Type of Process Continuous, mass Intermittent, job shop production, mainly batch production, assembly mainly fabrication 3. Product Standardized Varied, made to stock made to order 4. Demand Stable Fluctuating 5. Volume High Low 6. Equipment Special purpose General purpose 7. Workers Limited skills Varied skills

Comparison Of Product And Process Layouts PRODUCT LAYOUT PROCESS LAYOUT 8. Inventory Low in-process, High in-process, high finished goods low finished goods 9. Storage space Small Large 10. Material Fixed path Variable path handling (conveyor) (forklift) 11. Aisles Narrow Wide 12. Scheduling Part of balancing Dynamic 13. Layout decision Line balancing Machine location 14. Goal Equalize work at Minimize material each station handling cost 15. Advantage Efficiency Flexibility

Designing Process Layouts Minimize material handling costs Block Diagramming minimize nonadjacent loads use when quantitative data is available Relationship Diagramming based on location preference between areas use when quantitative data is not available

Block Diagramming Create load summary chart Calculate composite (two way) movements An Approach: Develop trial layouts minimizing number of nonadjacent loads

Block Diagramming Example LOAD SUMMARY CHART DEPARTMENT DEPT. 1 2 3 4 5 1 100 50 2 200 50 3 60 40 50 4 100 60 5 50

Initial & Final Designs

Block Diagrams

Example 1

Example 1 (cont.)

Example 1: Solution

Relationship Diagramming Used when quantitative data is not available Muther’s grid displays preferences Denote location preferences with weighted lines

Ranking System For Departments A - absolutely necessary E - especially important I - important O - okay U - unimportant X - undesirable

Relationship Diagramming Example Production O A Offices U I O Stockroom E A A X Shipping and Receiving U U U O O Locker Room O Toolroom

Original Layout

Revised Layout