6. facility layout (1)

7/31/2019 6. Facility Layout (1)

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Facility Layout


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Minimize material-handling costs

Utilize space efficiently

Utilize labor efficiently Eliminate bottlenecks

Facilitate communication and interaction

Reduce manufacturing cycle time

Reduce customer service time

Eliminate wasted or redundant movement

Increase capacity

Facilitate entry, exit, and placement of material, products, and people

Incorporate safety and security measures

Promote product and service quality Encourage proper maintenance activities

Provide a visual control of activities

Provide flexibility to adapt to changing conditions


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The relationship between volume-variety-flow providescrucial inputs to the layout problem.

Variety

Very low variety Medium Variety High VarietyOne-offExecutive

Flowattributes

Stream lined flowMultiple flow

pathsDisorganised

flowJumbled

flow

Volumeattributes

High Mid-volume Low One piece

Examples ofoperatingsystem

Process industry,Mass product/

serviceprovider

Batchmanufacturing

firms

Job shops,Customized

serviceProject shops

Types oflayoutused

Line layout:Product layout

Group technologylayout

Process layoutFixedpositionlayout


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Arrangement of resources on the basis of processcharacteristics of the resources available.

Sequence of visits for a product to different machinesdepends on routing.

When number of jobs to be processed in large thenthere will be enormous amount of crossings in the flow

of jobs. This poses challenges in material handling and

production control.

TYPES OF LAYOUT

1. Process Layout


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L

L

L

L

L

L

L

L

L

LM

M

M

M

D

D

D

D

D

D

D

D

G

G

G

G

G

G

A A AReceiving andShipping Assembly

Painting Department

Lathe Department MillingDepartment Drilling Department

GrindingDepartment

P

P


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The order in which resources are placed exactlyfollows the visiting sequence of the product asper routing information.

The required set of resources for every productis made available in a dedicated fashion.

Material handling and production control issuesare simpler.

2. Product Layout


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L

L

L

D

M

D

M

D

G

L

G

G

Product A

Product B

Product C


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PROCESS LAYOUT PRODUCT LAYOUT

ADVANTAGES

Sharing of specializedand costly equipment

More Flexibility Less vulnerable to

breakdowns

Standardizedproduct/ Processrouting

Operational controlsimpler

High output rate is

possible

DISADVANTAGES

Large inventory buildup Operational control is

difficult

Excess materialhandling

Low tolerance forbreakdown

Duplication ofequipments leading

to high capital costs Less flexibility due

to dedicatedresources


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3. GROUP TECHNOLOGY LAYOUT

Configuring resources that have mid-volume, mid-variety product portfolios.

GT is a philosophy that seeks to exploitcommonality in manufacturing and uses this as thebasis for grouping components and resources.

The implementation of GT is often known ascellular manufacturing.

In cellular manufacturing, the availablecomponents are grouped into part families &

corresponding to each part family, machine groupsare identified.

Production Planning and Control (PPC) becomessimpler.


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C

A

B Raw materials

Assembly

1

2

3

4

5

6 7

8

9

10

11

12


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3

6

9

Assembly

12

4

8 10

5

7

11

12

A B C

Raw materials

Cell 1

Cell 2

Cell 3


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4. FIXED POSITION LAYOUT

Product manufactured isbulky, difficult to moveand if often made in oneor a few pieces.

The specific orientationof the product willdictate the placement ofspecific resources

required for the process.


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Designing Process Layouts

Goal: minimize material handling costs

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


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Block Diagramming

Unit load

quantity in whichmaterial is normally

moved Nonadjacent load

distance farther thanthe next block

STEPS

create load summarychart

calculate composite(two way) movements

develop trial layoutsminimizing number of

nonadjacent loads


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Block Diagramming: Example

Department 1 2 3 4 5

Load Summary Chart

FROM/TO DEPARTMENT

1 100 502 200 503 60 40 50

4 100

605 50

1 2 3

4 5


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Block Diagramming: Example(cont.)

2 3 200 loads2 4 150 loads

1 3 110 loads1 2 100 loads4 5 60 loads3 5 50 loads2 5 50 loads3 4 40 loads1 4 0 loads1 5 0 loads

1 2 3

4 5

100 200

150 50 50

60

40

110

Grid 1

Nonadjacent Loads:110+40=150

1 2

3

4

5

100

200

150

50

50 6040

110

Grid 2

Nonadjacent Loads:0


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Relationship

DiagrammingProduction

Offices

Stockroom

Shipping andreceiving

Locker room

Toolroom

A A

AO

O

OO

O

U

UU

U

EX

I

A Absolutely necessaryE Especially importantI Important

O OkayU UnimportantX Undesirable


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(b) Relationship diagram of revised layout

Offices

Stockroom

Lockerroom

Toolroom

Shippingand

receiving

Production Key: AEIOUX

Relationship Diagrams: Example(cont.)


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Computerized layout Solutions

CRAFT Computerized Relative Allocation of Facilities

Technique

CORELAP Computerized Relationship Layout Planning

PROMODEL and EXTEND visual feedback

allow user to quickly test a variety of scenarios Three-D modeling and CAD

integrated layout analysis

available in VisFactory and similar software


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Designing Product Layouts

Line Balancing technique is employed fordesigning of product layouts

Estimation of exact number of resources and

the sequence of resources requiredTasks are optimally combined without

violating precedence constraints and certainnumber of workstations designed to complete

the tasksTries to equalize the amount of work at each

station


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productionActual

timeworkavailable

timeCycle

timeCycle

timestask

ns,workstatioltheoreticaofNumber T

N

timecyclestations)N(

timetaskTotalnutilizatioResourcesAverage

A


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Line Balancing Example

Task Time Required(in min.)

Precedes

A 2.2 B, C, D

B 3.4 E

C 1.7 E

D 4.1 F

E 2.7 F

F 3.3 G

G 2.6 --

Company operates one shift per day Available time per shift is 450 minutes

Production rate is 75 units/day

Cycle time = 450/75 = 6 minutes/part

NT = 20/6 = 3.33 = 4 stations


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Precedence Diagram

A

B

C

D

E

F G


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Task Assignment

Station

Time

Avail.

Elig.

Tasks

Will

Fit?

Task

Assign.

Idle

Time

1 6.0 A A A

3.8 B,C,D B,C B

0.4 C,D -- -- 0.4

2 6.0 C,D C,D D

1.9 C C C

0.2 E -- -- 0.2

3 6.0 E E E

3.3 F F F 0.0

4 6.0 G G G 3.4


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Line Balancing Solution

A

B

C

D

E

F G

Station 1

Station 2

Station 3

Station 4

6. facility layout (1)

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