MBA 8452 Systems and Operations Management Facility Layout

Objective: Manufacturing Design Be able to identify and explain the different Facilities Layout Be able to Solve Problems using Assembly Line Balancing

Facility Layout The physical arrangement of everything needed for production of goods or services equipment/machines raw materials/finished goods storage areas departments/workstations aisles and common areas

Benefits of Good Layout Overall, improved effectiveness and efficiency of the production system Higher utilization of space, equipment, and people Improved flow of information, materials, and work More convenience to the customer Improved employee morale and working conditions

Basic Production Layouts Process Layout Product Layout Group Technology (Cellular) Layout Fixed-Position Layout

Process Layout Similar activities and machines/operations are grouped together by functions into departments or work centers (job shops) Low-volume high-variety products Inputs follow different paths for processing Examples: department stores, universities, hospitals

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

Process Layout Example: Service Women’s lingerie dresses sportswear Shoes Cosmetics & Jewelry Entry & display area Housewares Children’s department Men’s

Designing Process Layout What factors might we consider when determining the locations of process areas, or departments? interdepartmental transportation material handling costs space & labor utilization flexibility etc.

Product Layout Activities and machines/operations are arranged sequentially in order by product specifications (flow shops) High-volume standardized products Inputs follow the same path Examples: assembly lines

Product Layout: An Example IN OUT

Assembly Line Balancing The Problem: how to organize jobs or tasks such that each station has the same work load/time for processing a unit? Station 1 Station 2 Station 3 5 min/unit 8 min/unit 3 min/unit 1 2 3 4 5 6 task What’s the problem here?

Line Balancing Example You’ve been assigned the job of setting up an electric fan assembly line with the following tasks: Task Time (Mins) Description Predecessors A 2 Assemble frame None B 1 Mount switch C 3.25 Assemble motor housing D 1.2 Mount motor housing in frame A, C E 0.5 Attach blade F Assemble and attach safety grill G Attach cord H 1.4 Test F, G

Step 1: Draw Precedence Diagram B D E F G H 2 3.25 1 1.2 .5 1.4 Which process step defines the maximum rate of production?

The Bottleneck Task Time (Mins) Description Predecessors A 2 Assemble frame None B 1 Mount switch C 3.25 Assemble motor housing D 1.2 Mount motor housing in frame A, C E 0.5 Attach blade F Assemble and attach safety grill G Attach cord H 1.4 Test F, G

Step 2: Compute Required Cycle Time If we are required to assembly 100 fans per day and we know that total production time per day is 420 mins = 7 hrs  60 min/hr, then What does this figure represent?

Step 3:Calculate Theoretical Minimum Number of Stations Therefore, Nt = 3 (always round up)

Step 4: Use Heuristic Rules to Assign Tasks to Stations most-following task rule Assign tasks in order of the largest number of following tasks longest task time rule Assign tasks in order of the longest task time Note: One of these rules can be used as the primary rule and another as the secondary tie-breaking rule

Step 4:Cont. If we try the most-followers rule as the primary rule and the longest task time as tie-breaking rule

Step 5: Evaluate Efficiency of the Line Note: If efficiency is unsatisfactory, rebalance using another rule to improve efficiency

Example: Some Further Questions What is the effective/achieved cycle time? Answer: 4.1 mins. What is the idle time of station 1? Total idle time of the assembly line? Answer: 0.2 mins and 1.25 mins, respectively Which station is the bottleneck? Answer: station 3

Product vs. Process Layouts PRODUCT LAYOUT PROCESS LAYOUT 1. Description Sequential arrangement Functional grouping of machines of machines 2. Process Continuous, mass prod. Intermittent, job shop 3. Product Standardized, make-to-stock Varied, make-to-order 4. Demand Stable Fluctuating 5. Volume High Low 6. Equipment Special purpose General purpose 7. Workers Limited skills Varied skills 8. Material handling Fixed path (conveyor) Variable path (forklift) 9. Goal Equalize work at Minimize material each station handling cost 10. Advantage Efficiency Flexibility

Retail Service Layout Goal--maximize net profit per square foot of floor space Humanistic considerations Ambient Conditions Spatial Layout and Functionality Signs, Symbols, and Artifacts

Fixed Position Layout What our our primary considerations for a fixed position layout?

Group Technology: Cellular Layout Dissimilar machines are grouped into work centers (cells) to process products with similar shapes and processing requirements

Cellular Layout Example: Original Process Layout 12 1 2 3 4 5 6 7 8 9 10 11 A B C Raw materials Assembly

Cellular Layout Example: Part Routing Matrix

Cellular Layout Example: Cell Formation

Cellular Layout Example: Revised Layout with Three Cells 12 1 2 3 4 5 6 7 8 9 10 11 A B C Raw materials Cell1 Cell 2 Cell 3 Assembly