TECHNICAL NOTE 6 FACILITY LAYOUT

Review and Discussion Questions

1. What kind of layout is used in a physical fitness center? Process layoutsimilar equipment or functions are grouped together, such as rowing machines in one area, and weight machines in another. The exercise enthusiasts mo e through the fitness center, following an esta!lished sequence of operations. ". What is the key difference !etween #$P and %&'(T? #$P is used to e aluate and include qualitati e factors and does not require numerical flow of items !etween departments. %&'(T is a quantitati e heuristic program that requires a quantitati e measure of interdepartmental work or information flow. ). What is the o!*ecti e of assem!ly+line !alancing? ,ow would you deal with the situation where one worker, although trying hard, is "- percent slower than the other 1- people on a line? The o!*ecti e is to create an efficient !alance !etween the tasks and workstations to minimi.e idle time. /f the employee is deemed alua!le, training may enhance his0her speed. /t is also possi!le to place him0her in the 1choice2 *o!, i.e., that workstation which has most idle time to ad*ust for the slowness. 'lso, faster workers may assist the slowpoke if the !alance and physical features of the line permit. 3. ,ow do you determine the idle+time percentage from a gi en assem!ly+line !alance? /dle+time percentage is gi en as 1!alance delay2 in the chapter. /t is simply one minus efficiency, where efficiency is equal to the sum of the task times di ided !y the num!er of workstations times the cycle time. 4. What information of particular importance do route sheets and process charts 5discussed in %hapter )6 pro ide to the layout planner? &oute sheets and process charts tell the layout planner the sequence of steps, the processing times, the equipment needed, and the delays and storage for the product to !e made. %learly, this information is critical to planning effecti e use of plant facilities. 7. What is the essential requirement for mixed+model lines to !e practical? The need to de elop a cycle mix that minimi.es in entory !uild+up while keeping cycle time constant.

88

Technical 9ote 7

:. Why might it !e difficult to de elop a ;T layout? a. <istinct parts families must exist. This requires de eloping and maintaining a computeri.ed parts classification and coding system. This can !e a ma*or expense. !. #e eral of each type of machine must !e a aila!le. This could !e an expensi e proposition, gi en the cost of purchasing and maintaining duplicate sets of machinery. c. Taking a machine out of a cluster should not ro! a cluster of all of its capacity. d. There may !e parts that cannot !e associated with a family and speciali.ed machinery that cannot !e placed in a cell !ecause of its general use. e. Training personnel to perform multiple types of tasks may !e initially difficult. =nion regulations and interpersonal pro!lems within a group working in a cell must !e resol ed !efore the cell is implemented. 8. /n what respects is facility layout a marketing pro!lem in ser ices? ;i e an example of a ser ice system layout designed to maximi.e the amount of time the customer is in the system. The facility layout must !e designed to meet customer expectations. =nlike fast food outlets, many finer restaurants will try to maximi.e the time that a customer is in system ia requiring a waiting period !efore seating customers 5e en those with reser ations6. >any customers will patroni.e the cocktail lounge 5thus enhancing profits6. ?. %onsider a department store. Which departments pro!a!ly should not !e located near each other? Would any departments !enefit from close proximity? 'sk the students to list the arious types of departments in a department store. (or example, typical departments include@ womenAs clothing, menAs clothing, childrenAs clothing 5!oth male and female6, shoes, health and !eauty aids, tools, camping supplies, home supplies, music, toys, etc. There are o! ious noncomplimentary departments such as tools and health and !eauty aids. 'n example of complimentary departments would !e menAs clothing and shoes. 1-. ,ow would a flowchart help in planning the ser icescape layout? What sorts of features would act as focal points or otherwise draw customers along certain paths through the ser ice? /n a supermarket, what departments should !e located first along the customersA path? Which should !e located last? The flowchart aids in monitoring the flow of customers through the ser ice area. This would pro ide a means for pro iding a layout that minimi.es the distance required for customers to reach the product. (ocal points could include B+mart style !lue lights and 1end cap2 displays. /n a supermarket, the first things in the customerAs path should !e shopping carts and con enience items such as a delicatessen. /t should !e remem!ered that certain popular items such as milk and eggs are kept at the rear of a store to cause the customer to walk through the store and increase impulse purchases.

8?

(acility $ayout

Pro !e"s
Pro!lem
Cffice $ayout

Type of Pro!lem
>ixed+ model #equence 'ssem!ly $ine Dalancing #$P >aterial ,andling %ost >odel

<ifficulty

9ew Pro!lem

>odified Pro!lem

%heck (igure in 'ppendix '

1 " ) 3 4 7 : 8 ? 111 1" 1)

Ees Ees Ees Ees Ees Ees Ees Ees Ees Ees Ees Ees Ees

>oderate >oderate >oderate >oderate <ifficult >oderate <ifficult <ifficult <ifficult >oderate >oderate >oderate <ifficult

Ees

Ees

1. %yprus %itrus %ooperati e has many alternati es. Delow is the existing layout with the steps in the process num!ered.

?-

Technical 9ote 7

#tudents will identify many possi!le alternati es. 'ssuming that no *o!s are com!ined, the following is a possi!ly@

". >ixed model !alance. &equired output0day@ "3D F "3< Process times@ 1" minutes per D, and 8 minutes per <. >odel sequence Cperation time >inicycle time D D < < < 8 8 8 "3 D D D D < < < 8 8 8 "3

1" 1" "3

1" 1" "3

1" 1" "3

?1

(acility $ayout

). a.

B
80

E
90

A
60

C
20

G
30

H
60

F D
50 30

!. % G production time per day0required output per day G 58 hour0day65)7-seconds0hour60"3- units per day G 1"- seconds per unit c.
Work station / // /// /I Task ' < D % H ( ; , Task time 748"?))7/dle time 1")-

d. Hfficiency G

T 3"G G .8:4 or 8:.4J N aC 351"-6

?"

Technical 9ote 7

a.

B
35

D
35

A
30

H
25

E C
30 15

G
40

F
65

!. c.

% G production time per day0required output per day G 534- minutes0day60)7-units per day G 1."4 minutes per unit or :4 seconds per unit

Work station / // /// /I

Task ' % H ( D ; < ,

Task time ))14 74 )4 3)4 "4

/dle time

114

d.

Hfficiency G

T ":4 G G .?1: or ?1.:J N aC 35:46

?)

(acility $ayout

4.

a.

% G production time per day0required output per day G 5:.4 hour per day6 5)7-- seconds per hour601---units per day G ": seconds per unit

!.
D
12

H
9

B
24

K
15

E
18

I
14

A
15

L
10

F C
6 7

J
7

G
11

Work station / // /// /I I

Task ' % D H ( / < ; , K B $

Task time 14 7 "3 18 : 13 1" 11 ? : 14 1-

/dle time 7 ) " 1

"

I/

c.

Hfficiency G

T 138 G G .?13 or ?1.3J N aC 75 ":6

d. &educe cycle time to "4 55:.4L)7--6011-- G "3.43 seconds6, which requires re!alancing the line or work o ertime@ 51-- units6 ": seconds per unit G ":-seconds or 34 minutes of o ertime.

?3

Technical 9ote 7

7.
100' 100' 100'

50'

C D

50'

50'

(rom0to ' to D ' to % ' to < D to % D to < % to < Total

<istances + rectilinear 1--A "--A "4-A 1--A 14-A 4-A

(low 1"4 44 14 14

%ost G distance M flow M N" N",--1-,--":,4-",--1,4-1,4-N33,4--

:.

a.

a
70

d
10

g
60

!
25

b
40

e
30

h
50

# "
20 25

c
45

f
20 15

!.

% G production time per day0required output per day G 5:.4 hour per day6 5)7-seconds per hour60)-- units per day G ?- seconds per unit

?4

(acility $ayout

c. d.

Ni =

T 31= G 3.47 C ?-

4 work stations

Work station / // /// /I I

Task a d g * c ! e h f / k l

Task time :17"4 34 3)4"14 ""4

/dle time 14 4 1-

1-

e. Hfficiency G f.

T 31G G .?11 or ?1.1J N aC 45?-6

&educe cycle time to 81 seconds per unit. This produces 5:.4 hours65)7-- seconds per hour6081 seconds per units G ))).) units. 'nother option is to work 34 minutes o ertime 5:.4 x 1-J G .:4 hour or 34 minutes6. There are many other options possi!le that are com!inations of these two options.

?7

Technical 9ote 7

8.

a.
2$%$8$&$16

2$%$10$&$20

5 10

4 100

200

300

15

2$%$3$&$6

!.

?:

(acility $ayout

c.

E'ce(( 20'

60'

d.

=nlikely. The nursesA station is not centrally located, and while patients may not go to the la! 5department 46 ery often, the nurses do. Thus, they will do a great deal of walking. /t would !e interesting to ha e the nursing staff de elop closeness ratings and contrast them with that of administrators and >.<.s.

?.

a.

% G production time per day0required output per day G 5: hour per day6 5)7-seconds per hour60:4- units per day G )).7 seconds per unit

!. c.

Ni =

T 118 = G ).41 C )).7

3 work stations

C
20

E
15

A
20

B
7

G
16

H
8

D
22

F
10

?8

Technical 9ote 7

d.
Work station / // /// /I I Task ' D < ( % H ; , Task time ": "" 1"14 17 8 /dle time 7.7 1.7 1).7 ".7 "4.7

e. f.

Hfficiency G

T 118 G G .:-" or :-."J N aC 45)).76

&educe cycle time to )". 9ew production le el is 5: hours0day65)7-- seconds per hour60)" seconds per unit6 G :8:.4 units per day. Therefore, they are 8-- O :8:.4 G 1".4 units short. Work 51".4 units 65)" seconds per unit6 G 3-- seconds or 7.7: minutes o ertime. 1--- O :8:.4 G "1".4 units short, work 5"1".4 units65)" seconds per unit6 G 78-seconds or 11).) minutes or 1.8? hours of o ertime. >ay want to consider re!alancing the line.

g.

1-.

a. There are 8P G 3-,)"- assignments possi!le if no constraints are applied. !. There are only two layout that satisfy all of the constraints.

$ayout /

A
1

B
2

G
3

H
4

C)*+,-a+d

E
5

F
6

C
7

D
8

??

(acility $ayout

$ayout //

A
1

C
2

G
3

H
4

C)*+,-a+d

E
5

F
6

B
7

D
8

The following ta!le contains the total materials handling costs for the two alternati e layouts.
Path '+D '+% '+< '+H '+( '+; '+, D+% D+< D+H D+( D+; D+, %+< %+H %+( %+; %+, <+H <+( <+; <+, H+( H+; H+, (+; (+, ;+, Total (low " 4 ) " ) 3 1 1 3 <istance $ayout 1 $ayout // 1"4 "4 1)3 )3 14 14 18 18 ""))18 18 "4 118 "14 1114 "18 1"4 "18 114 14 118 "))""18 18 14 14 11"4 "4 )3 )3 18 18 "4 "4 11$ayout / ":4 34 343 1"118 33"" %ost $ayout // 4:4 ))7 71"118 33)?

Dased upon total material handling cost, layout / is optimal.

1--

Technical 9ote 7

11.

a.

1 8
!.

2 7

3 6

4 5

Ad!ace.c- F#)/ D (,a.ce F#)/$0$D (,a.ce 112 35 10 350 115 1 40 40 213 30 10 300 217 4 10 40 314 45 10 450 315 5 20 100 415 30 10 300 417 3 30 90 516 30 10 300 617 20 10 200 718 15 10 $$$150 2),a# 2320

1". a. %ycle time G Production time per day0required output per day :.4 57-657-60?-- units G )- seconds !. Hfficiency G sum of task time05actual num!er of workstations x cycle time6 1"- sec0 535)-66 G 1 This is 1-- percent efficient c. To make ?-- units per shift, station ) will need to !e duplicated. Hfficiency formula G 1)4 0 545)-66 G .? This assume that each of the other Cperators still take )- seconds to complete. The system !ecomes less efficient due to the idle time at the parallel workstations.

1-1

(acility $ayout

1).

a.

A
1

D
1

B
2

F
2

E C
3 3

G
3

!.

% G production time per day0required output per day G 7minutes per hour6014 units per hour G 3 minutes per unit.

c.
Work station / // /// /I Task ' % H D ( < ; Task time 1 ) ) " " 1 ) /dle time 1 -

d.

Hfficiency G

T 14 G G .?):4 or ?).:4J N aC 35 3 6

1-"