1. MBA 8452 Systems and Operations Management
Facility Layout

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

3. 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

4. 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

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

6. 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

7. 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

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

9. 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.

10. 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

11. Product Layout: An ExampleIN
OUT

12. 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?

13. 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

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

15. 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

16. 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?

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

18. 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

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

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

21. 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

22. 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

23. 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

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

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

26. Cellular Layout Example: Original Process Layout12 1 2 3 4 5 6 7 8 9 10 11 A B C
Raw materials
Assembly

27. Cellular Layout Example: Part Routing Matrix

28. Cellular Layout Example: Cell Formation

29. Cellular Layout Example: Revised Layout with Three Cells12 1 2 3 4 5 6 7 8 9 10 11 A B C
Raw materials
Cell1
Cell 2
Cell 3
Assembly