MGT 4700 - Operations Management 4/23/2017 Facilities Chapter 5 Sec# 83930

Objectives Facility Layouts Process Layout Design Product Layout Design Hybrid Layouts Facility Location

Facility Layouts Layout characteristics Basic layouts Min handling cost, max utilization Safety, security, quality, flexibility Basic layouts Process layout Product layout Fixed position layout L M D G A Receiving and Shipping Assembly Painting Department Lathe Department Milling Drilling Department Grinding P

Compare 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 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 Somewhat static Complex & 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 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 (2 way) movements Develop trial layouts minimizing number of nonadjacent loads

Load Summary Chart Department A B C D E F A Radiology — 20 8 15 FROM/TO DEPARTMENT A Radiology — 20 8 15 B Lab — 30 10 2 C Waiting — 25 15 23 D Exam 25 15 25 — 7 E Surgery 4 4 5 — F Therapy 10 3 20 5 —

Relationship Diagramming Used when quantitative data is not available Muther’s grid table displays managers preferences for relative (pair wise) department locations Denote location preferences with weighted lines in a diagram

Muther’s Grid Table U A E O X I A Absolutely necessary Radiology Lab Waiting Exam Surgery Therapy A Absolutely necessary E Especially important I Important O Okay U Unimportant X Undesirable

Computerized Layout Solutions CRAFT – block diagramming CORELAP – relationship diagramming Simulation

Service Layouts Tailored to customer needs Max flow and exposure Computer programs consider Shelf space Demand Profitability Aesthetically pleasing

Designing Product Layouts Arranged in assembly line Precedence diagram of tasks Jobs divided into work elements Work elements assigned to workstations Workload balanced along the line

Line Balancing Balance the amount of work at each workstation Achieve a constant throughput with high efficiency Line balancing process Precedence diagram Desired cycle time Min number of workstations Group elements into workstations with acceptable efficiency

Precedence Table Work Element Precedence Time (min) A Tan leather — 30 B Dye leather A 15 C Shape case B 10 D Mold hinges and fixtures — 5 E Install hinges and fixtures C, D 10 F Assemble case E 10

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

Cellular Layouts Identify flow of similar parts B Raw materials Assembly 1 2 3 4 5 6 7 8 9 10 11 12 Identify flow of similar parts Group machines into cells Arrange cells to min material movement Locate shared machines where cells connect 3 6 9 Assembly 1 2 4 8 10 5 7 11 12 A B C Raw materials Cell 1 Cell 2 Cell 3

Direction of part movement within cell Manufacturing Cell In Out Worker 1 Worker 2 Worker 3 Direction of part movement within cell Saw Lathe Horizontal Milling Vertical Grinder Final inspection Finished part

FMS Layout Automated machining, material handling, tool changers Computer controlled system Designed around part sizes and flow times

Mixed Model Assembly Lines Produce multiple models in any order on one assembly line Issues in mixed model lines Line balancing U-shaped line Flexible workforce Model sequencing

Facility Location Types of facilities Location factors Heavy manufacturing Light industry Warehouses and distribution centers Retail and service Location factors Standard factors Global, regional, site factors Location incentives

Location Analysis Location factor rating Center-of-gravity technique Long-distance technique