1. Chapter 10 – Facility Layout
Operations Management by
R. Dan Reid & Nada R. Sanders
2nd Edition © Wiley 2005
PowerPoint Presentation by R.B. Clough - UNH

2. Learning Objectives Define layout planning and its importance
Identify and describe different types of layouts
Compare process layouts & product layouts
Describe the steps involved in designing process layouts
Explain the objectives of product layout design
Explain the advantages of hybrid layouts
Define the meaning of group technology & its importance to cellular layouts

3. What Is Layout Planning
Layout planning is determining the best physical arrangement of resources within a facility
Two broad categories of operations:
Intermittent processing systems
Continuous processing systems

4. Types of Layouts Process layouts: Product layouts: Hybrid layouts:
Group similar resources together
Product layouts:
Designed to produce a specific product efficiently
Hybrid layouts:
Combine aspects of both process and product layouts
Fixed-Position layouts:
Product is two large to move; e.g. a building

5. Process Layouts General purpose & flexible resources
Lower capital intensity & automation
Higher labor intensity
Resources have greater flexibility
Processing rates are slower
Material handling costs are higher
Scheduling resources & work flow is more complex
Space requirements are higher

6. Product Layouts Specialized equipment
High capital intensity & wide use of automation
Processing rates are faster
Material handling costs are lower
Less space required for inventories
Less volume or design flexibility

7. Designing Process Layouts
Step 1: Gather information:
Space needed, space available, importance of proximity between various units
Step 2: Develop alternative block plans:
Using trial-and-error or decision support tools
2 approaches
Relationship (REL) chart
From-to matrix
Can use both
Decision support systems are heuristic methods
Usually give a "good" solution
Solution may not be optimal (best solution)

8. Designing Process Layouts (2)
Step 3: Develop a detailed layout
Consider exact sizes and shapes of departments and work centers including aisles and stairways
Tools like drawings, 3-D models, and CAD software are often used

9. Process Layout Example
Block layout for a sports medicine clinic A
Radiology B
Laboratory C
Lobby & Waiting D
Examining Rooms E
Surgery & Recovery F
Physical Therapy

10. Process Layout Example (2)

11. Process Layout Example (3)

12. Process Layout Example (4)
Proposed Layout

13. Process Layout Example (5)

14. Office Layouts Office Layout Considerations:
Almost half of US workforce works in an office environment
Human interaction and communication are the primary factors in designing office layouts
People who need to talk frequently should be close to each other
One key layout trade-off is between proximity and privacy
Open concept offices promote understanding & trust
Flexible layouts with “office landscaping” help to solve the privacy issue in open office environments
A few closed rooms may be needed for private discussions, such as personnel matters.

15. Designing Product Layouts
Objectives
Produce the required number of units to meet demand
Use workers and equipment efficiently
Balance workload among employees

16. Designing Product Layouts (2)
Based on a precedence diagram
Assign tasks to work stations
Assign work stations to locations

17. Other Product Layout Considerations
Shape of the line (S, U, O, L):
Share resources, enhance communication & visibility, impact location of loading & unloading
Paced versus un-paced lines
Paced lines use an automatically enforced cycle time
Single or mixed-model lines

18. Hybrid Layouts Combine elements of both product & process layouts
Maintain some of the efficiencies of product layouts
Maintain some of the flexibility of process layouts
Examples:
Group technology & manufacturing cells – used in Just-in-Time manufacturing
Grocery stores

19. Designing Hybrid Layouts
One of the most popular hybrid layouts uses Group Technology (GT) and a cellular layout
GT has the advantage of bringing the efficiencies of a product layout to a process layout environment

20. Process Flows before the Use of GT Cells

21. Process Flows after the Use of GT Cells

22. Chapter 10 Highlights
Layout planning is deciding on the best physical arrangement of resources.
There are four basic types of layouts: process, product, hybrid, and fixed position.
Process layouts provide flexibility to make a variety of different products. Product layouts provide greater efficiency for one product.
The steps for designing process layouts are: gather space and closeness information, develop a block plan, and develop a detailed layout.

23. Chapter 10 Highlights (continued)
The steps for designing an product layout are: identify tasks and predecessors, determine output rate, determine cycle time, computing the theoretical minimum number of work stations, assigning tasks to workstations, and computing efficiency and balance delay.
Hybrids layouts combine elements from both types of layouts to increase efficiency.
Hybrid layouts combine GT analysis with cellular layout concepts .