1. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. DD DD GG GG GG MM MM MM AA AA L LL LL LL L Process Layout Chapter 7

2. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Implement changes 6 Redesign Process (Revise layout) 5 Redesigning a Process Through Layout Revision Document process 3 Define scope 2 Evaluate performance 4 Figure 7.1 Identify opportunity 1

3. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Absolute Locations (a) Original layout Frozen foods Dry groceries BreadVegetables Meats Figure 7.2

4. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Absolute Locations (b) Revised layout Frozen foods Dry groceries Bread Vegetables Meats Figure 7.2

5. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Layout Types Foundry Milling machines LathesGrinding PaintingDrills Office Welding Forging (a) Layout of a job shop Figure 7.3

6. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Layout Types (b) Layout of a production line Figure 7.3 Station 1Station 2Station 3Station 4

7. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Group Technology Machine 1 Machine 2 Machine 3 Machine 4 Machine 5 Materials in Finished goods out Figure 7.4 One Worker, Multiple Machines

8. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Group Technology Figure 7.5 Drilling DD DD Grinding GG GG GG Milling MM MM MM Assembly AA AA Lathing Receiving and shipping L LL LL LL L (a) Jumbled flows in a job shop without GT cells

9. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Group Technology (b) Line flows in a job shop with three GT cells Cell 3 LM G G Cell 1 Cell 2 Assembly area A A L M D L L M Shipping D Receiving G Figure 7.5

10. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Department Area Needed (ft 2 ) 1. Administration3,500 2. Social services2,600 3. Institutions2,400 4. Accounting1,600 5. Education1,500 6. Internal audit3,400 Total15,000 100' 150' Office of Budget Management 364 125 Figure 7.6

11. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Office of Budget Management Trips between Departments Department123456 1. Administration— 2. Social services— 3. Institutions— 4. Accounting— 5. Education— 6. Internal audit— 365610 811 39 2 1 100' 150' 364 125

12. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Office of Budget Management   Departments 1 and 6 close together   Departments 3 and 5 close together   Departments 2 and 3 close together Figure 7.7 100' 150' 15 6 100' 150' 364 125

13. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Office of Budget Management   Departments 1 and 6 close together   Departments 3 and 5 close together   Departments 2 and 3 close together Figure 7.7 100' 150' 15 6 3 100' 150' 364 125

14. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Office of Budget Management   Departments 1 and 6 close together   Departments 3 and 5 close together   Departments 2 and 3 close together Figure 7.7 100' 150' 15 63 2 4 100' 150' 364 125

15. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Office of Budget Management 100' 150' 364 125   Departments 1 and 6 close together   Departments 3 and 5 close together   Departments 2 and 3 close together Figure 7.7 100' 150' 15 632 4

16. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Distance Measures Euclidian Distance Rectilinear Distance d AB = (x A – x B ) 2 + (y A – y B ) 2 d AB = |x A – x B | + |y A – y B |

17. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Office of Budget Management 100' 150' 364 125 Load Distance Analysis Current Plan Proposed Plan DeptClosenessDistanceDistance PairFactor, wd wd Scoredwd Score 1,231326 1,3616318 1,4531515 1,56212212 1,610220110 2,3821618 2,412211 2,511122 3,432626 3,5932719 4,521212 5,612233 ld =112 ld =82 Example 7.2

18. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Office of Budget Management 100' 150' 364 125 Figure 7.8

19. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Office of Budget Management 100' 150' 364 125 Figure 7.9

20. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Out-and-Back Warehouse Figure 7.10 DockAisle Storage area 3556427155442735564271554427

21. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Zone Systems Figure 7.11 Click to add title Zones Control station Shipping doors Tractor trailer Overflow Feeder lines

22. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Green Grass, Inc. Big Broadcaster

23. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster

24. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster ABolt leg frame to hopper40None BInsert impeller shaft30A CAttach axle50A DAttach agitator40B EAttach drive wheel6B FAttach free wheel25C GMount lower post15C HAttach controls20D, E IMount nameplate18F, G Total244 WorkTimeImmediate ElementDescription(sec)Predecessor(s) Example 7.3

25. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster ABolt leg frame to hopper40None BInsert impeller shaft30A CAttach axle50A DAttach agitator40B EAttach drive wheel6B FAttach free wheel25C GMount lower post15C HAttach controls20D, E IMount nameplate18F, G Total244 WorkTimeImmediate ElementDescription(sec)Predecessor(s) Example 7.3

26. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster ABolt leg frame to hopper40None BInsert impeller shaft30A CAttach axle50A DAttach agitator40B EAttach drive wheel6B FAttach free wheel25C GMount lower post15C HAttach controls20D, E IMount nameplate18F, G Total244 WorkTimeImmediate ElementDescription(sec)Predecessor(s) 40 A Example 7.3

27. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster ABolt leg frame to hopper40None BInsert impeller shaft30A CAttach axle50A DAttach agitator40B EAttach drive wheel6B FAttach free wheel25C GMount lower post15C HAttach controls20D, E IMount nameplate18F, G Total244 WorkTimeImmediate ElementDescription(sec)Predecessor(s) 40 30 B A Example 7.3

28. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster ABolt leg frame to hopper40None BInsert impeller shaft30A CAttach axle50A DAttach agitator40B EAttach drive wheel6B FAttach free wheel25C GMount lower post15C HAttach controls20D, E IMount nameplate18F, G Total244 WorkTimeImmediate ElementDescription(sec)Predecessor(s) 40 50 B C A 30 Example 7.3

29. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster ABolt leg frame to hopper40None BInsert impeller shaft30A CAttach axle50A DAttach agitator40B EAttach drive wheel6B FAttach free wheel25C GMount lower post15C HAttach controls20D, E IMount nameplate18F, G Total244 WorkTimeImmediate ElementDescription(sec)Predecessor(s) 40 50 30 40 D B C A Example 7.3

30. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster ABolt leg frame to hopper40None BInsert impeller shaft30A CAttach axle50A DAttach agitator40B EAttach drive wheel6B FAttach free wheel25C GMount lower post15C HAttach controls20D, E IMount nameplate18F, G Total244 WorkTimeImmediate ElementDescription(sec)Predecessor(s) 40 6 50 E 30 40 D B C A Example 7.3

31. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster ABolt leg frame to hopper40None BInsert impeller shaft30A CAttach axle50A DAttach agitator40B EAttach drive wheel6B FAttach free wheel25C GMount lower post15C HAttach controls20D, E IMount nameplate18F, G Total244 WorkTimeImmediate ElementDescription(sec)Predecessor(s) 40 6 50 E 30 25 40 D B F C A Example 7.3

32. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster ABolt leg frame to hopper40None BInsert impeller shaft30A CAttach axle50A DAttach agitator40B EAttach drive wheel6B FAttach free wheel25C GMount lower post15C HAttach controls20D, E IMount nameplate18F, G Total244 WorkTimeImmediate ElementDescription(sec)Predecessor(s) 40 6 50 15 E 30 25 40 D B F C A G Example 7.3

33. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster ABolt leg frame to hopper40None BInsert impeller shaft30A CAttach axle50A DAttach agitator40B EAttach drive wheel6B FAttach free wheel25C GMount lower post15C HAttach controls20D, E IMount nameplate18F, G Total244 WorkTimeImmediate ElementDescription(sec)Predecessor(s) 40 6 20 50 15 E 30 25 40 H D B F C A G Example 7.3

34. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster ABolt leg frame to hopper40None BInsert impeller shaft30A CAttach axle50A DAttach agitator40B EAttach drive wheel6B FAttach free wheel25C GMount lower post15C HAttach controls20D, E IMount nameplate18F, G Total244 WorkTimeImmediate ElementDescription(sec)Predecessor(s) 40 6 20 50 15 18 E 30 25 40 H I D B F C A G Example 7.3

35. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster Figure 7.12 40 6 20 50 15 18 E 30 25 40 H I D B F C A G

36. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster Example 7.4 40 6 20 50 15 18 E 30 25 40 H I D B F C A G Desired output rate = 2400/week Plant operates 40 hours/week

37. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster 40 6 20 50 15 18 E 30 25 40 H I D B F C A G Desired output rate = 2400/week Plant operates 40 hours/week r = 2400/40 = 60 units/hour Example 7.4

38. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster 40 6 20 50 15 18 E 30 25 40 H I D B F C A G Desired output rate = 2400/week Plant operates 40 hours/week r = 2400/40 = 60 units/hour c = 1/60 = 1 minute/unit = 60 seconds/unit Example 7.4

39. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit 40 6 20 50 15 18 E 30 25 40 H I D B F C A G Desired output rate = 2400/week Plant operates 40 hours/week Example 7.4

40. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit 40 6 20 50 15 18 E 30 25 40 H I D B F C A G Desired output rate = 2400/week Plant operates 40 hours/week TM = 244 seconds/60 seconds = 4.067 or 5 stations Example 7.4

41. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit 40 6 20 50 15 18 E 30 25 40 H I D B F C A G Desired output rate = 2400/week Plant operates 40 hours/week TM = 244 seconds/60 seconds = 4.067 or 5 stations Efficiency = [244\5(60)]100 = 81.3% Example 7.4

42. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% 40 6 20 50 15 18 E 30 25 40 H I D B F C A G Desired output rate = 2400/week Plant operates 40 hours/week TM = 244 seconds/60 seconds = 4.067 or 5 stations Efficiency = [244\5(60)]100 = 81.3% Example 7.4

43. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% 40 6 20 50 15 18 E 30 25 40 H I D B F C A G CummIdle StationCandidateChoiceTimeTime Example 7.5

44. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% 40 6 20 50 15 18 E 30 25 40 H I D B F C A G CummIdle StationCandidateChoiceTimeTime S1AA4020 Example 7.5

45. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% 40 6 20 50 15 18 E 30 25 40 H I D B F C A G CummIdle StationCandidateChoiceTimeTime S1AA4020 Example 7.5

46. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% S1 40 6 20 50 15 18 E 30 25 40 H I D B F C A G CummIdle StationCandidateChoiceTimeTime S1AA4020 Example 7.5

47. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% S1 40 6 20 50 15 18 E 30 25 40 H I D B F C A G CummIdle StationCandidateChoiceTimeTime S1AA4020 S2B,CC5010 Example 7.5

48. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% S1 40 6 20 50 15 18 E 30 25 40 H I D B F C A G CummIdle StationCandidateChoiceTimeTime S1AA4020 S2B,CC5010 Example 7.5

49. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% S1 S2 40 6 20 50 15 18 E 30 25 40 H I D B F C A G CummIdle StationCandidateChoiceTimeTime S1AA4020 S2B,CC5010 Example 7.5

50. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% S1 S2 40 6 20 50 15 18 E 30 25 40 H I D B F C A G CummIdle StationCandidateChoiceTimeTime S1AA4020 S2B,CC5010 S3B,F,GB3030 Example 7.5

51. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% S1 S2 40 6 20 50 15 18 E 30 25 40 H I D B F C A G CummIdle StationCandidateChoiceTimeTime S1AA4020 S2B,CC5010 S3B,F,GB3030 Example 7.5

52. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% S1 S2 40 6 20 50 15 18 E 30 25 40 H I D B F C A G CummIdle StationCandidateChoiceTimeTime S1AA4020 S2B,CC5010 S3B,F,GB3030 Example 7.5

53. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% S1 S2 40 6 20 50 15 18 E 30 25 40 H I D B F C A G CummIdle StationCandidateChoiceTimeTime S1AA4020 S2B,CC5010 S3B,F,GB3030 E,F,GF555 Example 7.5

54. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. S1 S2 Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% 40 6 20 50 15 18 E 30 25 40 H I D B F C A G CummIdle StationCandidateChoiceTimeTime S1AA4020 S2B,CC5010 S3B,F,GB3030 E,F,GF555 Example 7.5

55. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% S1 S2 S3 40 6 20 50 15 18 E 30 25 40 H I D B F C A G S1AA4020 S2B,CC5010 S3B,F,GB3030 E,F,GF555 CummIdle StationCandidateChoiceTimeTime Example 7.5

56. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% S1 S3 S2 40 6 20 50 15 18 E 30 25 40 H I D B F C A G Example 7.5

57. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Line Balancing Big Broadcaster c = 60 seconds/unit TM = 5 stations Efficiency = 81.3% S1 S2 S3 S5 S4 Figure 7.13 40 6 20 50 15 18 E 30 25 40 H I D B F C A G

58. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Solved Problem 1 BF E ACD B F E A C D Figure 7.14 Figure 7.15 TRIPS BETWEEN DEPARTMENTS DEPTABCDEF A—8395 B —3 C —89 D —3 E —3 F —

59. To Accompany Krajewski & Ritzman Operations Management: Strategy and Analysis, Seventh Edition © 2004 Prentice Hall, Inc. All rights reserved. Solved Problem 2 20 E 145 H 130 I 25 D 80 B 15 F 50 C 40 A 120 G 115 J Figure 7.16