3/9/2010

Agenda
„
„
Definitions
Introduction
Facilities Planning
„ Types of facilities layout problems
„ The objectives of facility layout
„ Requirements of layout
y strategy
gy By: NEHAL ELSAYAR
„ Basic types of layout
9 Layout by product
9 Layout by process
9 Layout by fixed material location To: Dr. / Ashraf S. Youssuf
„ Which type of layout to use
„ Factors affecting facility layout
„ Layout design procedure
„ Comparative analysis of layout types
2 1

layout
From: The Oxford Pocket Dictionary of Current English / Date: Definitions
2008

1. Facilities layout refers to an optimum arrangement of different facilities including

lay·out . the way in which the parts of something are
2.
arranged or laid out: changing the layout of the
ground floor. elaborate HTML layouts. the way in 3.
which text or pictures are set out on a page: the 4.
5.
layout is uncluttered and the illustrations are helpful
helpful.
6.
the process of setting out material on a page or in a
work: doing layout for newspapers and magazines. a 7.
thing arranged or set out in a particular way: a model 8.
railroad layout. ,a position in which the body is 9.
extended, the head upright, the legs held straight and
together, and the arms held out to the sides.
man, machine, equipment, material, etc.
configuration of work centers and equipment to ensure a smooth and uninterrupted
flow of materials and work- in -process through a facility.
Layout – the physical location of all the facilities, machines, equipment and staff
belonging to an operation
Flow – the way in which transformed resources travel through the operation
plant layout
p y problem
p is to find the best arrangement
g of p
physical
y facilities to
provide an efficient operation.
The layout problem may occur in machines, workstations, storage areas and
aisles and also in other places such as grocery stores, hospitals, airports, etc.
The complexity of the design problem generally requires that a sequential process
be used.
Developing the layout is an important step it serves to establish the physical
relationships between activities.
Aim: “to achieve an optimal interface of the facilities, equipment, and personnel
that constitute the operations management system.” (Note: Facility layout must be
planned simultaneously with product design, process selection, material /people
handling, packaging and not down stream.)

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Introduction (cont’d …1/5) Agenda

• Facilities planning is the process planning new facilities and „ Definitions
revising or expanding old facilities „ Introduction
– determines how an activity’s tangible fixed assets best support „ Types of facilities layout problems
achieving the activity’s objective „ The objectives of facility layout
• Facility layout is the process of determining the placement of „ Requirements of layout strategy
departments, workgroups,
departments workgroups workstations,
workstations machines
machines, and stock
stock- „ B i ttypes off layout
Basic l t
holding points within a facility are determined, and requires the 9 Layout by product
following inputs:
9 Layout by process
– Specification of system objectives in terms of output and flexibility
9 Layout by fixed material location
– Estimation of product or service demand on the system
„ Which type of layout to use
– Processing requirements in terms of number of operations and
amount of flow between departments and work centers „ Factors affecting facility layout
– Space requirements for the elements in the layout „ Layout design procedure
– Space availability within the facility itself „ Comparative analysis of layout types

6 5

Introduction (cont’d …3/5) Introduction (cont’d …2/5)

Facilities Planning Objectives Why Facilities Planning?
• 20-50% of the total expenses within manufacturing
are attributed to materials handling
• Minimize material handling cost – effective facilities planning can reduce the material handling
• Minimize overall production time costs by at least 10-30%
• To be competitive, very few companies will be able to
• Effectively utilize existing space
retain all of their old facilities or layouts
• Provide for employee convenience – productivity improvements through elimination or reduction
• Assure workplace safety and comfort of unnecessary activities
– improved health and safety
• Facilitate the manufacturing process – to conserve & reduce consumption of energy.
• Facilitate the organizational structure – must conform to new rules, regulations, and standards
– lower the risk of fire, lower maintenance costs, etc.
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Introduction (cont’d …5/5) Introduction (cont’d …4/5)

Facilities Planning Activities Facilities Planning Process
Specify or update activities
Facilities
Planning
Determine requirements

Facilities Facilities Continuous No

Is it feasible to
Location Design Determine new
improvement & incorporate new activities
facility location
maintenance on existing site?

Yes

Facilities Facility Layout Handling Systems Develop & evaluate alternative plans
Systems Design Design Design
10
Select & implement plan 9

Types of Layout Problems

(cont’d…1/2)

The facilities layout can be classified according to: Process design

Processes that Processes that

Design Products Produce Products and
and Services Services
„ The type of facility under consideration e.g. Supply Network
Concept Generation Design
¾ Manufacturing plants
Screening
¾ Commercial facilities, e.g., shops, offices, bank etc. Preliminary Design
Layout
and Flow
¾ Service facilities, e.g., hospitals, post offices etc. Evaluation and
Improvement Process Job
¾ Residential facilities, e.g., Houses, apartments etc. Prototyping and
Technology Design

¾ Cities, townships. final design

¾ Recreational facilities, e.g., parks, theatres etc.

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Objectives of Facility Layout Types of Layout Problems

(cont’d…1/2) (cont’d…2/2)
• A facility layout problem may have many objectives. In the context of
manufacturing plants, minimizing material handling costs is the most The facilities layout can be classified according to:
common one.
• Other objectives include efficient utilization of
– space „ The nature of layout, it can be categorized into 4
– labor types as follows
• Eliminate
– bottlenecks ¾ Planning a completely new facility.
– waste or redundant movement ¾ Expanding or relocating an existing facility.
• Layout design requires substantial investments of resources ¾ Rearrangement of existing layout.
• It is not easily changed and therefore involves long term
¾ Minor modifications in present layout.
commitments
• It influences the cost and efficiency of short term operations

14 13

Requirements of layout strategy Objectives of Facility Layout

(cont’d…2/2)

A competitive layout strategy must be fully integrated with:

• Facilitate
• product design and volume (product strategy) – organization structure
• process equipment and capacity (process strategy) – communication and interaction between workers
• material handling and packaging systems (manufacturing logistics)
– manufacturing process
• quality of work life (human resource strategy)
• building
g and site constraints ((location strategy)
gy) – visual control
• marketing strategy • Minimize
– manufacturing cycle time or customer flow time
Impact of economic layout on operating cost
In the 1990s, TACO Industries, a US manufacturer of circulatory pumps for – investment
residential and industrial customers regained its ability to compete by re- • Provide
engineering its facility strategy to be product oriented rather than process. By
focusing on products, TACO redesigned its plant layout to match its – convenience, safety and comfort of the employees
manufacturing strategies for different products.
– flexibility to adapt to changing conditions

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Constraints on layout & Requirements

Advantages of a good layout strategy:
for a good layout
„ Constraining factors
• Product design & volume
• Process equipment & capacity • Minimize manufacturing (service) cycle time thereby maximizing throughput
• Building & site of the system.
• Minimize “set up time” of equipment and material handling.
• Quality of work life • Optimal
O ti l utilization
tili ti off llabour
b and
d space. F
For example,
l ththere iis lless work
k iin
Requirements for a good layout process inventory
• an understanding of capacity and space requirements • Meet international environmental and safety standards
• Facilitate maintenance
• selection of appropriate material handling equipment
• Improves worker morale
• decisions regarding environment and aesthetics • Can be used by marketing to increase sales
• identification and understanding of the requirements for
information flow
• identification of the cost of moving ( load x distance) between
the various work areas
18 17

Characteristics of a good layout Source

The facilities layout decision
procedure Manufacturing & Back Office
Service Operations
Face-to-Face Services

1. Straight-line flow 1. Easily understood service flow

pattern

Decision 1 Project process 2. Minimal back tracking 2. Proper waiting facilities

Volume and Jobbing process
variety 3. Predictable production time 3. Easy communication with
Batch process
Process type Mass process customers
Continuous process 4. Little w.i.p. storage 4. Customer surveillance easily
Decision 2 maintained.
Strategic
g
performance Fixed position layout 5. Open plant visibility 5. Clear exit and entry points
objectives Basic layout type Process layout with sufficient check out
Cell layout capabilities.
Product layout
6. Controlled bottlenecks 6. Departments and processes
Decision 3 layout – controlled visibility.
7. Work stations close 7. Balance between waiting and
Detailed design The physical position of all
service area
of layout transforming resources
8. Minimum material movement 8. Minimum walking (load x
distance)
Flow of transformed resources 9. Only necessary mat. handling 9. Lack of clutter.
10. Flexible response to 10. High sales volume per square
20 changing foot of facility 19
conditions

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Elements of Defining Layout The nature of the basic layout types

Layout involves the relative positioning of transformed resources

within operations and functions and the allocation of tasks to the Manufacturing Basic layout Service
resources, which together dictate the flow of transformed process types types process types
resources through the operation or function Projectprocesses
Project processes Fixed Professional
position layout services

Relative positioning of
transforming resources
Jobbing processes
Allocation of tasks to Functional layout
transforming resources
Service shops
Batch processes
Cell layout

Mass processes Mass services

Flow of transformed Product layout
resources
Continuous processes

22 21

Design Techniques Six (6) Types of Layout Strategies

Fixed-position layout - large bulky projects such as ships and

• Fixed position – resource location analysis
• Functional layout – flow charts and relationship
charts
• Cell layout – product flow analysis
• Product layout – assembly line balancing techniques
buildings
Process-oriented layout - deals with low-volume, high-variety
production (“job shop”, intermittent production)
Office layout
y -ppositions workers,, their equipment,
q p , and
spaces/offices to provide for movement of information
Retail/service layout - Marketing focus. Allocates shelf space and
responds to customer behavior. See also R&H “Servicescapes”
discussion and slides on service layout.
Warehousing and Storage layout – trade off space and material
handling.
Product-oriented layout - seeks the best personnel and machine
use in repetitive or continuous production

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I. Project or Fixed Position (Product)

Layout (cont’d…1/7) Basic Types of Layout

Volume
Lathe Press Grind High Product
W Planning
S a Department
t r
o Product
P d t
e
r
Production Layout Product
h
a o volume Family
g
Medium Fixed Location
Planning
Process
u Department
e s Layout Layout
e Group Technology
Fixed Materials Layout Process
Location
Planning
Weld Paint Assembly Planning
Department
Department

Low
Low Medium High Variety

26
Product variety 25

Project or Fixed Position (Product) Project or Fixed Position (Product)

Layout (cont’d…3/7) Layout (cont’d…2/7)

This is the layout for project type systems in which the major
component is kept at a fixed position and all other materials,
components, tools, machines, workers etc. are brought and
assembly or fabrication is carried out.
Thi ttype off layouts
This l t is
i now nott usedd very commonly l ads
d ththe
machines required for manufacturing work are big and
complicated.
The fixed position layout is used only when it is difficult to move
the major component and fabrication is to be carried out e.g.
production of ships.

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Project or Fixed Position (Product) Project or Fixed Position (Product)

Layout (cont’d…5/7) Layout (cont’d…4/7)
Some of the major advantages of fixed position • Transformed resources remain stationary
layout are as follows: • Transforming resources move as necessary
i. The handling requirements for major unit are minimized. • Effectiveness is governed by:
ii. High adaptability to the variety of product and intermittent demand.
iii. The responsibility for quality can be pin-pointed.
• Scheduling of transforming resources (e.g.
iv. The capital investment is minimum. access to construction site)
v. Material movement is reduced.
vi. Promotes job enlargement by allowing individuals or teams to • Reliability of transforming resources (e.g.
perform the “whole job”. deliveries by different contractors)
vii. Continuity of operations and responsibility results from team.
viii. Highly flexible; can accommodate changes in product design,
product mix, and product volume.
• Examples: shipbuilding, construction projects,
ix. Independence of production centers allowing scheduling to achieve some surgeries, restaurants, mainframe
minimum total production time.
computer maintenance
30 29

Project or Fixed Position (Product) Project or Fixed Position (Product)

Layout (cont’d…7/7) Layout (cont’d…6/7)

Limitations:

i. Increased movement of personnel and equipment.

ii. Equipment duplication may occur.
iii. Higher skill requirements for personnel.
iv. General supervision required.
v. Cumbersome and costly positioning of material and machinery.
vi. Low equipment utilization.

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Process or Functional Layout II. Process or Functional Layout

(cont’d…2/8) (cont’d…1/8)

Lathe Lathe Drill Weld Weld

W
S a
t r
o Lathe Lathe Drill Paint Paint e
r h
a o
g u
e Mill Mill Grind Assembly s
e

Mill Mill Grind Assembly

34 33

Process or Functional Layout Process or Functional Layout

(cont’d…4/8) (cont’d…3/8)

This type of layout is developed for process focused

The functional layout is more suited for low-volumes of
production (batch production) and particularly when
the product is not standardized. It is economical
when flexibility is the basic system requirement.
The flexibility may be in terms of the routes through the
system, volume of each other, and the processing
requirements of the items.
systems.
The processing units are organized by functions into
departments on the assumption that, certain skills and
facilities are available in each department.
Similar equipments and operations are grouped together,
e.g., milling, foundry, drilling, planting, heat treatment etc.
The use of process-focused systems is very wide both in
manufacturing and other service facilities such as
hospitals. Large offices, municipal services etc.

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Process or Functional Layout (cont’d…6/8) Process or Functional Layout

(cont’d…5/8)

Advantages • Similar processes (or processes with similar needs)

i. Better utilization of machines can result; consequently, fewer machines are located together
are required. • Utilisation of transforming resources is improved –
ii. A high degree of flexibility exists relative to equipment or man power convenience of grouping similar processes
allocation for specific tasks.
iii. Comparatively low investment in machines is required. • Transformed
T f d resources move through
th h th
the operation
ti
iv. The diversity of tasks offers a more interesting and satisfying according to their needs
occupation for the operator. • Different products ≡ different needs ≡ different routes
v. Specialized supervision is possible. • Complex flow pattern in the operation
vi. Greater incentive to individual worker.
vii. More continuity of production in unforeseen conditions like breakdown,
• Examples: supermarkets, some machine
shortages, absenteeism etc. manufacture, hospitals

38 37

Process or Functional Layout (cont’d…8/8)

Process or Functional Layout (cont’d…7/8)
„ An example of a functional layout in a library
showing the path of just one customer
Loan books in subject order On-line and
CD-ROM Limitations
access room
i. Since longer flow lines usually exist, material handling is
more expensive.
ii. Production planning and control systems are more
Study desks To involved.
journal
Company reports

sack
iii. Total production time is usually longer.
iv. Comparatively large amounts of in-process inventory
Enquiries

Current
journals result.
v. Space and capital are tied up by work in process.
vi. Because of the diversity of the jobs in specialized
Reference departments, higher grades of skill are required.
section
Reserve
collection
Store Counter staff
room Copying area
40 39
Entrance Exit

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Cellular or Group Layout (cont’d…2/12) III. Cellular or Group Layout

(cont’d…1/12)

It is special type of functional layout on which the

facilities are clubbed together into cells.
Lathe Drill Grind Assembly
This is suitable for systems designed to use the
W
concepts, principles and approaches of ‘group S a
gy , such a layout
technology’, y offers the advantages
g of t
Mill Assembly Weld Paint
r
o e
mass production with high degree if flexibility. r h
a o
we can employ high degree of automation even if the g u
number of products are more with flexible e Press Lathe Drill Press Assembly s
e
requirements.
In such a system the facilities are grouped into cells Grind Drill Assembly Drill Grind
which are able to perform similar type of functions for
a group of products.
42 41

Cellular or Group Layout (cont’d…4/12) Cellular or Group Layout (cont’d…3/12)

• Machines or services grouped into cells

• Cells determined by the process requirements of the
family of product/services they transform
• Could be considered mini product layouts
• Can simplify a functional/process layout
• Flexible
• Duplicates some resources
• Examples: some computer component manufacture,
department stores, ‘lunch’ products areas in
supermarkets, certain units in hospitals

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Cellular or Group Layout (cont’d…6/12) Cellular or Group Layout (cont’d…5/12)

• Every cell contains a group of machines which are dedicated to the
production of a family of parts.
• One of the problems is to identify a family parts that require the same
Advantages group of machines.
i. Increased machine utilization. • These layouts are also called as group technology layouts.
ii. Team attitude and job enlargement tend to occur.
iii. Compromise between product layout and process layout, with associated
g
advantages. Enter
iv. Supports the use of general purpose equipment. Machines
v. Shorter travel distances and smoother flow lines than for process layout.
vi. Reduced material handling and transit time Worker 2 Worker
vii. Reduced setup time 3
viii. Reduced work-in-process inventory Worker 1
ix. Better use of human resources
x. Better scheduling, easier to control and automate Exit

Key: Product route

Worker route
46 45

Cellular or Group Layout (cont’d…8/12)

Cellular or Group Layout (cont’d…7/12)
The ground floor plan of a department store
showing the sports goods shop-within-a-shop
retail ‘cell’
Limitations
Books i. General supervision required.
and
Footwear Sports shop Menswear ii. Higher skill levels required of employees than for product layout.
videos iii. Compromise between product layout and process layout, with associated
limitations.
iv. Depends on balanced material flow through the cell; otherwise, buffers and work-
Perfume i
in-process storage
t are required.
i d
& jewellery v. Lower machine utilization than for process layout.
vi. Sometimes cells may not be formed because of inadequate part families.
Confectionery, Elevators vii. Some cells may have a high volume of production and others very low. This results
newspaper, in poorly balanced cells.
magazines and Women’s clothes viii. When volume of production changes, number of workers are adjusted and workers
stationery
are reassigned to various cells. To cope with this type of reassignments, workers
must be multi-skilled and cross-trained.
ix. Sometimes, machines are duplicated in different cells. This increases capital
investment.
Luggage
and gifts
Entrance

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Cellular or Group Layout (cont’d…10/12) Cellular or Group Layout (cont’d…9/12)

m1 m4 m6 The three major types of arrangement in the GT cells are the

m1 m2 m3 m4 m5 single-row, multi-rows or loop layout
m2 m5 The single-row layout, or sometimes known as the GT flow line
layout, is used when the parts assigned to the group follow the
m3 q
same machine sequence.
(a) single-row layout (b) multi-row layout The multi-row layout, or the GT cell layout, permits parts to move
from any machine to any other machine.
m1 m2 m1 m2 The flow of parts may not be unidirectional in this layout. The GT
m8 m3 centre layout, on the other hand, is based on a functional
robot m3 m7 m4 arrangement of the machines and is suitable when the product-
m6 m5 mix changes frequently.
m5 m4

(c)semi-circular layout (d) loop layout

Types of layout in the GT cell 50 49

Cellular or Group Layout Cellular or Group Layout (cont’d…11/12)

(cont’d…12/12)
Group Technology (Cellular Layout/Work Cells)

• Conversion of a process focused layout into a miniature version of a product The single row layout may assume different configuration such as semi-circular, linear
layout to increase productivity. or U-shaped. The machines in the single row layout are arranged as close as
possible to the sequence of operations of all the parts processed in the layout in
• Dissimilar machines are grouped together into work cells to perform work to order to minimize traveling time.
produce goods that can be grouped into families on the basis of common
processing requirements, materials, geometrical shape, size, weight, function. In this layout, the sequence of operations are normally similar from one part to another
andd the
h material
i lh
handling
dli equipment
i usedd are normallyll conveyors.
• These cells are temporary and can shrink or expand in size based upon product
demand.
• Flexible Manufacturing Systems represent a special case of group technology The multi-row layout is usually linear and the movements of parts can be between
by integrating computer aided manufacturing systems and automated material any machines in different rows as well as in the same row, which is suitable for
flow using computer controlled machines for a wide range of manufacturing FMS.
operations.
• Example: production of components for a medical device such as a pace maker. In the loop layout, machines are arranged in an oval path with unidirectional
A cell can be assigned to produce and be responsible for inspection of a movement.
complete component.

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Cellular or Group Layout Cellular or Group Layout (cont’d…)

Example (cont’d…1/10) Group Technology (Cellular Layout/Work Cells)

Work Cell Floor Plan

Assembly
Saws Drills Office
4 6 7 9

5 8
2 10 12

1 3 11 Work Cell
Tool Room
A B C Raw materials
54 53

Cellular or Group Layout Cellular or Group Layout

Example (cont’d…3/10) Example (cont’d…2/10)

Machines • The previous slide shows a facility in which three

Parts 1 2 3 4 5 6 7 8 9 10 11 12 parts A, B, C flow through the machines.
A x x x x x • The next slide provides the information in a matrix
form which includes some other parts D, E, F, G, H.
B x x x x
• The rows correspond to the parts and columns to the
C x x x machines.
D x x x x x • Just by interchanging rows and columns, eventually a
E x x x matrix is obtained where the “X” marks are all
concentrated near the diagonal. This matrix provides
F x x x
the cells. For example, parts A, D and F require
G x x x x Machines 1, 2, 4, 8 and 10 which forms a cell.
H x x x 56 55

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Cellular or Group Layout Cellular or Group Layout

Example (cont’d…5/10) Example (cont’d…4/10)

Machines Machines
Parts 1 2 4 3 5 6 7 8 9 10 11 12 Parts 1 2 4 3 5 6 7 8 9 10 11 12
A x x x x x A x x x x x
D x x x x x B x x x x
B x x x x C x x x
C x x x D x x x x x
E x x x E x x x
F x x x F x x x
G x x x x G x x x x
H x x x 58
H x x x 57

Cellular or Group Layout Cellular or Group Layout

Example (cont’d…7/10) Example (cont’d…6/10)

Machines Machines
Parts 1 2 4 8 3 5 6 7 9 10 11 12 Parts 1 2 4 8 3 5 6 7 9 10 11 12
A x x x x x A x x x x x
D x x x x x D x x x x x
F x x x B x x x x
B x x x x C x x x
C x x x E x x x
E x x x F x x x
G x x x x G x x x x
H x x x 60
H x x x 59

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Cellular or Group Layout Cellular or Group Layout

Example (cont’d…9/10) Example (cont’d…8/10)

Machines Machines
Parts 1 2 4 8 10 3 6 9 5 7 11 12 Parts 1 2 4 8 10 3 5 6 7 9 11 12
A x x x x x A x x x x x
D x x x x x D x x x x x
F x x x F x x x
C x x x B x x x x
G x x x x C x x x
B x x x x E x x x
E x x x G x x x x
H x x x 62
H x x x 61

Cellular or Group Layout

IV. Product or Line Layout (cont’d…1/7) Example (cont’d…10/10)

Assembly
Lathe Drill Grind Drill

S
A W 8 10 9 12
s a
t s r
Press Bend Drill
o e
r
e
m h 11
a b o 4 Cell1 6 Cell 3
g
Mill Drill l u Cell 2
e y s
e 7
Lathe Lathe Drill
2 1 3 5

Raw materials A C B
64 Each of A, B, C now visits only one area, minimizing jumping 63

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Product or Line Layout (cont’d…3/7) Product or Line Layout (cont’d…2/7)

This type of layout is developed for product systems.

In this type of layout only one product, or one type of
product, is produced in a given area.
In a case of product being assembled
assembled, this type of
layout is probably known as an ‘assembly line’.
The work centers are organized in the sequence of
appearance.
The raw material enters at one end of the line and goes
from one another rapidly with minimum of work-in-
process storage and material handling.
66 65

Product or Line Layout (cont’d…5/7) Product or Line Layout (cont’d…4/7)

A product layout in a paper manufacturing operation
• Sometimes called line layout
• Locates the transforming resources entirely for the convenience
of the transformed resources
• Transformed resources follow a specified route – the sequence
of activities that are required matches the sequence in which the
processes have been located
• Flow is clear, predictable, easy to control
• Examples: car assembly, paper manufacture, self-service
canteen

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Product or Line Layout (cont’d…7/7) Product or Line Layout (cont’d…6/7)

Advantages
Limitations i. Since the layout corresponds to the sequence of operations, smooth and logical
flow lines result.
i. A breakdown of one machine may lead to a complete stoppage of the line that ii. Since the work from one process is fed directly into the next, small in-process
follows that machine. inventories result.
ii
ii. Since the layout is determined by the product
product, a change in product design may iii.
iii Total
T t l production
d ti ti time per unitit is
i short.
h t
require major alternations in the layout.
iv. Since the machines are located so as to minimize distances between consecutive
iii. The “pace” of production is determined by the slowest machine. operations, material handling is reduced.
iv. Supervision is general, rather than specialized. v. Little skill is usually required by operators at the production line; hence, training is
v. Comparatively high investment is required, as identical machines (a few not fully simple, short, and inexpensive.
utilized) are sometimes distributed along the line. vi. Simple production planning control systems are possible.
vii. Less space is occupied by work in transit and for temporary storage.

70 69

Mixed or Hybrid Layout (cont’d…2/2) Mixed or hybrid Layout (cont’d…1/2)

A restaurant complex with all four basic layout types
„ Combination of the layouts discussed.
„ A sample hybrid layout that has characteristics of group, process and product layout
Cell layout buffet is shown in the following figure.
„ A combination of group layout in manufacturing cells, product layout in assembly
area, and process layout in the general machining and finishing section is used.
Fixed-position layout
service restaurant
Line TM DM TM TM
Dessert

layout
Starter
buffet

buffet

cafeteria
BM TM TM
Main course
buffet Service line
Preparation
Oven

Functional layout kitchen

Cool room
Freezer Vegetable preparation Grill
72 71

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Which type of layout to use? (cont’d…1/6) Advantages and disadvantages

The fixed position layout is used ideally for a project situation i.e. Fixed
Functional Cell Product
for one product of a different type. position
layout layout layout layout
As the quantity increases the production operations can be broken
Very high product High product and Can give good
down into different work centers and material can be allowed to and mix flexibility. mix flexibility. compromise. Low unit costs for
move rather than the machines,, and a p process layout
y is Product/customer
P d t/ t Relatively
R l ti l robust
b t F t throughput.
Fast th h t
high volume.

preferred. Advantages not moved. in the case of Opportunities for

disruptions. Group work can specialization of
With further increase in volume i.e. with mass production the High variety of result in good equipment.
advantages of production line can be better derived and a tasks for staff. Easy to supervise. motivation.

product layout is desirable. Can have low mix

Very high unit Low utilization. Can be costly to flexibility.
The break-even analysis comprise the production volume of the costs. rearrange existing
three basic layouts i.e., product, process and fixed position Disadvantages
Can have very layout. Not very robust to
Scheduling space high WIP. disruption.
layout. and activities can Can need more
be difficult. Complex flow. plant. Work can be very
repetitive.

74 73

Which type of layout to use? (cont’d…3/6)

Which type of layout to use? (cont’d…2/6)
Volume – Variety Influence
Flow is Low High
Volume
intermittent
High

Fixed-position
layout
Regular flow morre feasible

Process
layout
Variety

Cell layout

Product
layout
Low

Flow
becomes
continuous 76 75
Regular flow more important

19
 3/9/2010

Which type of layout to use? (cont’d…4/6)

Which type of layout to use? (cont’d…5/6)
Process Type vs. Layout Type
Cost vs. Layout
The basic layout types have different fixed and variable cost characteristics that seem to
determine which one to use
Manufacturing Basic layout Service
functional types types functional types
Costs

Project processes Fixed-position layout

Professional
services
i
Jobbing
processes Functional layout
Service shops
Batch processes

Cell layout

Use Use
Use product Mass services
Use fixed- functional cell Mass processes
position Product layout
Volume Continuous processes
78 77

Plant layout factors (cont’d…1/3) Which type of layout to use?

Cost vs. Layout (cont’d…6/6)
Costs

Fixed-position

The design of any layout is governed by a Functional

number if factors and the best layout is the
Cell
one that optimizes all the factors.
As discussed by Muther (1995) the factors Product

influencing any layout are categorized into

the following eight groups:
? ? ? ?
Use product
Volume
Use fixed-position Use cell or product
Use fixed-position or functional Use functional or cell or product
80
Use functional Use functional or cell 79

20
 3/9/2010

Plant layout factors (cont’d…3/3) Plant layout factors (cont’d…2/3)

v. Waiting factor: includes permanent and temporary
storages and delays and their locations.
vi. Service factor: includes service relating to
employee facilities such as parking lot, locker
rooms,, toilets,, waiting
g rooms etc. service relating
g to
materials in terms of quality, production control,
scheduling, despatching, waste control; and service
relating to machinery such as maintenance.
vii. Building factor: includes outside and inside building
features and utility distribution and equipment.
viii. Change factor: includes versatility, flexibility and
expansion.
i. Material factor: includes design, variety, quantity,
the necessary operations, and their sequences.
ii. Man factor: includes direct workers, supervision,
and service help,
p, safetyy and manpower
p utilization.
iii. Machinery factor: includes the process, producing
equipment and tools and their utilization.
iv. Movement factor: includes inter and
intradepartmental transport and handling at the
various operations, storage and inspections, the
materials handling equipments.

82 81

Layout design procedure (cont’d…1/13) Layout Procedures

Detailed layout design: What makes a good layout?
Two different categories:
• Inherent safety
• Length of flow Construction - involves developing a new layout
• Cl it off flflow
Clarity
“from scratch”
• Staff conditions
• Management coordination
• Accessibility Improvement - generate layout alternatives
• Space utilisation based on an existing layout
• Long-term flexibility

84 83

21
 3/9/2010

Layout design procedure (cont’d…3/13) Layout design procedure (cont’d…2/13)

Some important guidelines that help in the
layout design are: The overall layout procedure can be considered
i. Plan from whole to details to be composed of four phases:
ii. First plan the ideal and then move to the
practical aspects Phase I Location
Phase II General Overall Layout
iii. Material requirements should be central to
the planning of process and machinery Phase III Detailed layout
Phase IV Installation
iv. Modify the process and machinery by
different factors to plan the layout
86 85

Layout design procedure (cont’d…5/13) Layout design procedure (cont’d…4/13)

v. Planning the material flow pattern and developing Through there is always an overlap in the different
the overall material handling plan. phases of layout design the major steps that have
to be followed in the layout design are outlined as
vi. Calculation of equipment requirements and work follows:
centers. i. Statement of the problem in terms of its objectives,
vii. Planning g of individual work centers. scopep and factors to be considered.
viii. Selection of material handling equipment. ii. Collection of basic data on sales forecasts,
ix. Determining storage requirements. production volumes, production schedules, part
lists, operations to be performed, work
x. Designing activity relationships. measurement, existing layout, building drawings
xi. Planning of auxiliary and service facilities. etc.
xii. Calculation of space requirements and allocation of iii. Analysis of data and its presentation in the form of
activity areas. various charts.
iv. Designing the production process.
88 87

22

Layout design procedure (cont’d…7/13)
Fixed Position
• Design a layout to maximise the effectiveness of the
transforming resources
• Resource location
• Define site and available locations
• Define resource centres and their requirements
• Devise evaluation criteria
• Match resource centres to available locations
• Preliminary allocation on site criteria
• Amend allocation using relative-location criteria
90
Layout design procedure (cont’d…9/13)
Cell Layout
• Cells are a compromise between the flexibility of
process layout and the simplicity of product layout
• Design of cell layout requires decisions as to
• Extent and nature of cells to adopt – examining
amount and of resources located within the cell
• Resources to allocate to cells – cluster analysis /
parts family coding
• Production flow analysis
92
3/9/2010
Layout design procedure (cont’d…6/13)
xiii. Development of Plot Plan.
xiv. Development of Block Plan.
xv. Development of detailed layouts in terms of steps
(vii) to (xi).
(xi)
xvi. Evaluation, modification and checking of layouts.
xvii. Installation of layouts.
xviii.Follow up.
89
Layout design procedure (cont’d…8/13)
Functional Layout
• Complex due to large number of options possible
• Flow charts and relationship charts
• Some of the information requirements
• Area required by each work centre
• Constraints on the shape of work area allocated
• Degree and direction of flow between work areas
• Desirability of work centres proximity to each other
or to fixed points in the layout
91
23
 3/9/2010

Layout design procedure Layout design procedure (cont’d…10/13)

Product Layout (cont’d…11/13)

Cycle time of product layouts
• Time between completed products /
services emerging from the operation
• Calculated using projected demand for
period and the amount of production time
available in that period
• Cycle time = time available /
number to be processed
94
Product Layout
Decisions required are:
• What cycle time is needed?
• How many stages are needed?
• How should the task-time variation be dealt
with?
• How should the layout be balanced?
• How should the stages be arranged?
93

Layout design procedure Layout design procedure

Product Layout (cont’d…13/13) Product Layout (cont’d…12/13)

• Arranging the stages: long thin or short fat • Number of stages

• Requires cycle time and total quantity of work
• Shape of the line
• Number of stages = Total work content /
• Staffing flexibility and balance cycle time
• Rework • Task time variation
• Handling • Variance around the mean for each stage
• Passage • Balancing work time allocation
• Teamwork • Minimise balancing loss
• Balancing Techniques

96 95

24
 3/9/2010

SYSTEMATIC FACILITIES
PLANNING
„ Systematic:
Systematic:
Organized, disciplined rational approach to a
problem
„ Facilities::
Facilities Systematic
y Layout
y Planning
g ((SLP))
Building, production & material handling
equipment, land, access (supporting
equipment)
„ Planning::
Planning
Decide a course of action based on facts and
analysis
98 97

SYSTEMATIC FACILITIES
Systematic Layout Planning
PLANNING
• Systematic layout planning accounts for the „ Systematic Facilities Planning fits in this
importance of having each department located next
to every other department category:
– guided by trial and error „ Common Sense
– switch departments then check the results of the “closeness”
closeness
score
„ Pi E
Prior Experience
i
• Why us SLP? „ Simple Numerical Methods
– numerical flow of items between departments can be „ Visual Representations
impractical to obtain, or
– interdepartmental flow method does not account for any of
the qualitative factors that may be crucial to the placement Practical Perceptiveness
decision

100 99

25
 3/9/2010

Systematic Layout Planning procedure Systematic Layout Planning

Relationship Chart The SLP procedure was presented by Francis and

From-To Chart
White (1974).
Once the appropriate information is gathered, a flow
analysis can be combined with an activity analysis to
develop the relationship diagram.
diagram
Space considerations when combined with the
relationship diagram lead to the construction of the
space relationship diagram.
Based on the space relationship diagram, modifying
considerations and practical limitations, a number of
alternative layouts are designed and evaluated.
102 101

The Phases of Systematic Layout Planning

(cont’d …2
…2/2) The Phases of Systematic Layout Planning
(cont’d …1
…1/2)

Phase I LOCATION
IV
II OVERALL LAYOUT
Level off Detail

III III DETAIL LAYOUTS

Time IV INSTALLATION
II
Phase I: Phase II: Phase III: Phase IV:
I
MFG
BLDG
NEW BLDG B
HIWAY

D D
A
MAIN
BLDG C
104 103

Time

26

Richard Muther’s Simplified Systematic
Layout Planning (1994) (cont’d …1/6)
1. Chart the relationships
106
Richard Muther’s Simplified Systematic
Layout Planning (1994) (cont’d …3/6)
3. Diagram activity relationships
108
3/9/2010
Muther’s Systematic Layout Planning
Procedure (SLP)
1. It uses as its foundation the activity relationship chart.
2. A material flow analysis (from-to-chart) and an activity
relationship analysis (activity relationship chart) are
performed
3. Relationship diagram is developed
4. Determine the amount of space to be assigned each activity
(use departmental service and area requirement sheets)
5. Space templates are developed for each planning
department this leads to the space relationship diagram
6. Layout alternatives are developed
105
Richard Muther’s Simplified Systematic
Layout Planning (1994) (cont’d …2/6)
2. Establish space requirements
107
27
 3/9/2010

Richard Muther’s Simplified Systematic Richard Muther’s Simplified Systematic

Layout Planning (1994) (cont’d …5/6) Layout Planning (1994) (cont’d …4/6)
5. Evaluate alternative arrangements 4. Draw space relationship layouts

110 109

Systematic Layout Planning (cont’d …1/3) Richard Muther’s Simplified Systematic

Layout Planning (1994) (cont’d …6/6)
A Absolutely Necessary
E Especially Important
I Important 6. Detail the selected layout plan
O Ordinary Closeness O.K.
U Unimportant
X Undesirable
A and X > E > I > O > U

O
X E
A

112 111

28
 3/9/2010

Systematic Layout Planning Systematic Layout Planning (cont’d …2/3)

(cont’d …3/3)

114 113

Prevailing Methodology: Process Layout:

Systematic Layout Planning (SLP) Systematic Layout Planning
1. Material 2. Activity
Flows Relationships z Numerical flow of items between departments
z Can be impractical to obtain
3. REL z Does not account for the qualitative factors that may be
Chart
crucial to the placement decision
z Systematic Layout Planning
4. REL
Diagram z Accounts for the importance of having each department
5. Space located next to every other department
Requirements
z Is also guided by trial and error
6. Space REL
Diagram z Switching departments then checking the results
7. Space
Availability of the “closeness” score
8. Layout
Alternatives Departments ≡ Activities 116 115

29

Systematic Layout Planning (cont’d …2/7)
„ Layout planning Heuristics are of two
types:
- Those which start with an initial layout
and proceed to modify it (These are
called Improvement Heuristics), and
- Those which start the Layout analysis
from scratch (Construction Heuristics.)
118
Systematic Layout Planning (cont’d …4/7)
„ Therefore, its goal is to Minimize the Total
Cost of Moving Items between Departments.
„ It attempts to improve an Initial Layout by
switching the locations of pairs of
departments.
It begins with one department, AND one by
„
one Analyzes the effect on total travel cost of
switching those departments.
120
3/9/2010
Systematic Layout Planning (cont’d …1/7)
Systematic Layout Planning is essentially an
organized Trial-and-Error Approach.
„ Therefore, unless all possible layouts are considered,
There is no wayy to know if an Optimal
p Solution been
Reached.
„ However, there are a number of Heuristics that can
be used to Generate good solutions Quickly.
„ Heuristics: Trial-and-error solutions that do not give
optimal solution but easy to apply.
117
Systematic Layout Planning (cont’d …3/7)
„ The most widely known algorithm
requiring an Initial Layout developed by
hand is the Computerized Relative
All
Allocation
ti off Facilities
F iliti Technique
T h i
(CRAFT).
CRAFT was developed for situations in
„
which Materials Handling Costs were a
major consideration.
119
30
 3/9/2010

Systematic Layout Planning (cont’d …6/7) Systematic Layout Planning (cont’d …5/7)

„ While the Original CRAFT was used only for

„ These heuristics start with an empty single-story buildings,
floor area and proceed to fit „ An extension of CRAFT called SPACECRAFT
departments
departments. can handle
h dl multistory
lti t buildings.
b ildi
„ ALDEP can be used in a multistory „ Some examples of Construction Heuristics
building. It generates many alternative include CORELAP (Computerized Relationship
layouts. Layout Planning) and ALDEP (Automated
Layout Design Program).

122 121

Systematic Layout Planning—Example 1

(cont’d…1/9) Systematic Layout Planning (cont’d …7/7)
Reasons for Closeness

Code Reason

1 Type of customer
„ CORELAP on the other hand, can lay
out only single story buildings.
2 E
Ease off supervision
ii
„ Both programs use closeness codes
3 Common personnel
defined in the Activity Relationship
4 Contact necessary
Charts.
5 Share same price

6 Psychology

124 123

31
 3/9/2010

Systematic Layout Planning—Example 1 Systematic Layout Planning—Example 1

(cont’d…3/9) (cont’d…2/9)
Relating Reasons and Importance Importance of Closeness
Area
From To Line Numerical
2 3 4 5 (sq. ft.)
Value Closeness
I U A U code weights
1. Credit department 100
6 -- 4 -- A Absolutely necessary 16
U I A
2. Toy department 400
-- 1 16
1,6 E Especially important 8
U X
3. Wine department 300 I Important 4
-- 1
X
4. Camera department 100 O Ordinary closeness OK 2
1

5. Candy department 100

U Unimportant 0
X Undesirable 80
Letter Closeness rating
Number Reason for rating 126 125

Systematic Layout Planning—Example 1 (cont’d…5/9) Systematic Layout Planning – Example 1

Initial Relationship Diagram Relating Reasons and Importance (cont’d…4/9)
The Starting Solution
Area
From To
2 3 4 5 (sq. ft.)
I U A U
1. Credit department 100
E 6 -- 4 --
1 3
U I A
2. Toy department 400
-- 1 16
1,6
I U U Note here U X
4 3. Wine department 300
that the (1) -- 1
Credit Dept. NoteX here that
2 5 4. Camera department 100
and (2) Toy the 1(2) Toy Dept.
A and the (5)
5. Candy department Dept. are 100
given a high Candy Dept. are
Closeness rating Letter rating of 6. given a high
128 Reason for rating Number
rating of 6. 127

32
 3/9/2010

Systematic Layout Planning - Example 1 Systematic Layout Planning - Example 1

Initial Relationship Diagram (cont’d…7/9) Initial Relationship Diagram (cont’d…6/9)
3
1 E 3 The number of lines
2 here represent paths
I U U required to be taken in
4
transactions between
the departments. The
5 4 2 5
A more lines, the more
Note here again, Depts. (1) and the interaction between
(2) are linked together, and departments.
1 Depts. (2) and (5) are linked
together by multiple lines or
required transactions.
130 129

Systematic Layout Planning – Example 1 Systematic Layout Planning—Example 1

Initial and Final Layouts (cont’d…9/9) Initial and Final Layouts (cont’d…8/9)
Initial Layout (ignoring space constraints)
5 2 4 2
3 20 ft
3 1 5 1 4
Note in the 5 2 4
50 ft Final Layout
that Depts.
Initial Layout Final Layout (1) and (5)
3 1
are not both
Ignoring space and Adjusted by square
building constraints placed
footage and building
size
directly next
to Dept. (2).
132 131

33
 3/9/2010

Systematic Layout Planning: Example 2 Systematic Layout Planning: Example 2

(cont’’d …2/3)
(cont (cont’’d …1/3)
(cont

Scaled activity
relationship 4
diagram
A
E
I relationships
relationships

1 5 10 8

3 2 9

6 7

134 133

Systematic Layout Planning: Example 3 Systematic Layout Planning: Example 2

(cont’’d …1/11)
(cont 11) (cont’’d …3/3)
(cont

Alternative
„ A small accounting Firm, GUNTAŞ Accounting, layouts
has rented Space in a new one-floor building.
„ The firm has allocated 6000 square meter to
its seven departments as follows:

136 135

34
 3/9/2010

Systematic Layout Planning: Example 3 Systematic Layout Planning: Example 3

(cont’’d …3/11)
(cont 11) (cont’’d …2/11)
(cont 11)

In the first step of Systematic Layout Planning,

we analyze interactions between departments
AND we assess the desirability of placing
departments together.
„ The firm has carefully analyzed its operations
to Determine the importance of Locating
specific departments Close Together.
„ The results of this analysis are summarized in
the following Activity Relationship Chart:

138 137

Systematic Layout Planning: Example 3 Systematic Layout Planning: Example 3

(cont’’d …5/11)
(cont 11) (cont’’d …4/11)
(cont 11)

140 139

35
 3/9/2010

Systematic Layout Planning: Example 3 Systematic Layout Planning: Example 3

(cont’’d …7/11)
(cont 11) (cont’’d …6/11)
(cont 11)

„ Since the space assignments are given before, the

following Activity Relationship Diagram shows the
relative Sizes of Each Department:
„ This Activity Relationship Diagram is
essentially an Illustration of the
Information Contained in the Activity
Relationship Chart.
Chart
„ All departments in this diagram are
Represented by equal size boxes.
„ The next step is to anticipate the space
required for each Department.

142 141

Systematic Layout Planning: Example 3 Systematic Layout Planning: Example 3

(cont’’d …9/11)
(cont 11) (cont’’d …8/11)
(cont 11)

„ Some examples of Practical Limitations in this „ In this stage, there are no restrictions on
case were as follows:
the length and width of each department
„ 1- It is considered that offices for partners
(2) the
(2), th meeting
ti room (7) and d the
th reception
ti „ In the final step, we should develop and
area (1) should be close to each other. evaluate several alternative layouts,
„ 2- It is important that the juniors (4) and the while keeping in mind the Practical
managers (3) be close together. Limitations.

144 143

36
 3/9/2010

Systematic Layout Planning: Example 3 Systematic Layout Planning: Example 3

(cont’’d …11
(cont 11//11)
11) (cont’’d …10
(cont 10//11)
11)

„ As a result of these limitations, An alternative floor

plan is developed as follows:

„ This floor plan may be revised many times until

the best layout has been found.
„ Usually departments are positioned one by one,
Beginning with the department with the Highest
A or E ratings.

146 145

Systematic Layout Planning Systematic Layout Planning

Analyze product/ resource
flow
Identify non-flow factors,
Where significant
Flow diagram
From-to chart Layout Planning Steps
• Arrange work centers in order of dominant flow (objective
Activity-Relationship
diagram is to ensure resource/product flow at optimum cost/time)

Assess data and arrange work Activity arrangement diagram • A

Analyze
l product/resource
d t/ flow
fl ( Flow
Fl diagram/
di / From-To
F T
area diagram)

Determine space arrangement Space relationship diagram • Include non-flow factors & combine with flow factors
plan • Determine space requirements
Fit space arrangement in to Floor plan • Fit space arrangement into available space
available space Detailed layout plan
148 147

37