1. Facility Layout
Part b

2. Computerized Layout Solutions
Classification A
Construction Algorithm
CORELAP, ALDEP, PLANET
Improvement Algorithm
CRAFT
Classification B
Relationship Diagramming Based
CORELAP, ALDEP
From-To Chart (Block Diagramming) Based
PLANET, CRAFT

3. CRAFT Example
Consider a facility with four departments A, B, C, and D. The initial layout and dimensions of each department area are given in the diagram (a). The distance and flow information for this initial layout are given in matrices (b) and (c). Develop an improved layout using the two-way exchange procedure.
Please Note in CRAFT:
Distances are measured from the centroid of the area.
Two-Way Interchanges imply that departments with common boundaries and/or same areas can be switched.

4. CRAFT Example

5. CRAFT Example (cont.)

6. CRAFT Example (cont.)

7. CRAFT Example (cont.)

8. CRAFT Example (cont.)
Possible Two-Way Interchanges: AB AC AD BD CD

9. CRAFT Example (cont.)

10. CRAFT Example (cont.)

11. CRAFT Example (cont.)

12. CRAFT Example (cont.)

13. CRAFT Example (cont.) Next, possible Two-Way Interchanges: AB AC AD BC
BD (Takes it to the initial layout; can be ignored) CD

14. CRAFT Example (cont.)

15. CRAFT Example (cont.) Next, possible Two-Way Interchanges:
AB (Takes it to the previous layout; can be ignored) AC AD BC CD

16. CRAFT Example (cont.)

17. CRAFT Example (cont.)

18. Service Layouts Usually process layouts due to customers needs
Minimize flow of customers or paperwork
Retailing tries to maximize customer exposure to products
Computer programs consider shelf space, demand, profitability
Layouts must be aesthetically pleasing

19. Designing Product Layouts
Product layouts or assembly lines
Develop precedence diagram of tasks
Jobs divided into work elements
Assign work elements to workstations
Try to balance the amount work of each workstation

20. Hybrid Layouts Cellular layouts Flexible Manufacturing Systems
Mixed Model Assembly Lines

21. Cellular Layouts 1. Identify families of parts with similar flow paths
2. Group machines into cells based on part families
3. Arrange cells so parts movement is minimized
4. Locate large shared machines at point of use

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

23. Part Routing Matrix MACHINES PARTS 1 2 3 4 5 6 7 8 9 10 11 12
A x x x x x
B x x x
C x x x
D x x x x x
E x x x
F x x x
G x x x x
H x x x

24. Part Routing Matrix Reordered To Highlight Cells
MACHINES
PARTS
A x x x x x
D x x x x x
F x x x
C x x x
G x x x x
B x x x
H x x x
E x x x

25. Cellular Layout Solution

26. Advantages Of Cellular Layouts
Reduced material handling and transit time
Reduced setup time
Reduced work-in-process inventory
Better use of human resources
Easier to control
Easier to automate

27. Disadvantages Of Cellular Layouts
Inadequate part families
Poorly balanced cells
Expanded training and scheduling of workers
Increased capital investment

28. Flexible Manufacturing Systems
Automated machining operations
Automated material handling
Automated tool changers
Computer controlled system
Designed around size of parts processed & average processing time for parts
Can process wide variety of items quickly

29. FMS Layouts

30. Open Field FMS Layout

31. 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