FACILITY LAYOUT

Process Layout

Facility Layout

A Layout problem may be to

determine develop develop

the location for a new machine,

a new layout for an existing production plant, a layout for a new production plant,

etc.

Facility Layout
Facility layout can be defined as the process by which the placement of departments, workgroups within departments, workstations, machines, and stock-holding points within a facility are determined.

Facility Layout

A Layout problem may arise due to

changes in the design of a product, addition or deletion of a product, change in the demand of a product, changes in the design of the process, addition or deletion of a process, obsolescence/replacement of equipment, frequent accidents, changes in legal/environmental regulations, competitive cost reduction, etc.

Objectives of Facility Layout

Reduce congestion that impedes movement of people or material Minimize material handling costs Provide safety and comfort to employees Utilize labour efficiently Increase morale Utilize available space effectively and efficiently Provide ease of supervision Facilitate co-ordination and face-to-face communication Minimize investment in equipment Minimize production time Maintain flexibility of arrangement and operation

Basic Layout Types

Product or Line Layouts - uses standardized processing operations to achieve smooth, high-volume flow Process or Functional Layouts - can handle varied processing requirements Project or Fixed-Position - the product or project remains stationary, and workers, materials, and equipment are moved as needed Cellular Layouts Combination Layouts

Process Layout: Interdepartmental Flow

Given The flow (number of moves) to and from all departments The cost of moving from one department to another The existing or planned physical layout of the plant Determine The best locations for each department, where best means maximizing flow, while minimizing costs

Graphic Approaches to Layout Planning

Facility Outline Locations

Graphic Approaches to Layout Planning

From A B C D E F A 4 No. of Moves to B C D E 7 4 10 7 2 8 6 10 F 5 3 -

From-To or Travel Chart

Graphic Approaches to Layout Planning

Deptt. No. of links A 3 B 5 C 3 D 2 E 5 F 4

Graphic Approaches to Layout Planning

Deptt. No. of links A 3 B 5 C 3 D 2 E 5 F 4

Number of Links or Number of Moves?

Graphic Approaches to Layout Planning

A
4 5 10 7 6 10 7 2 8

F
3

Graphic Approaches to Layout Planning

A Possible Facility Layout

Process Layout: Systematic Layout Planning

Numerical flow of items between workcentres Can be impractical to obtain Does not account for the qualitative factors that may be crucial to the placement decision Systematic Layout Planning Accounts for the importance of having each department located next to every other department Is also guided by trial and error Switching workcentres then checking the results of the closeness score

Input Data and Activities

1. Flow of Materials

2. Activity Relationships

Muthers
Systematic Layout
5. Space Requirement

3. Relationship Chart

4. Relationship Diagram

6. Space Available

7. Space Relationship Diagram 8. Modifying Considerations 9. Practical Limitations

Planning

10. Develop Alternative Layouts

11. Evaluation

Example of Systematic Layout Planning: Relating Reasons and Importance

From 1. Credit department 2. Toy department 3. Wine department 4. Camera department 5. Candy department Closeness rating Letter 2 I 6 3 U -U -To 4 E 4 I 1 U --

5 U -A 1,6 X 1 X 1

Area (sq. ft.) 100 400 300 100 100

Relationship Chart or REL Chart

Reason for rating Number

Example of Systematic Layout Planning: Relating Reasons and Importance

From 1. Credit department 2. Toy department 3. Wine department 4. Camera department 5. Candy department Closeness rating Letter To I 6 2 U -3 A 4 4 U -A 1,6 X Note 1

Area (sq. ft.) 100 400

U I -- here 1 Note U that the (1) -Credit Dept.

and (4) Camera Dept. are given a high rating of A.

300 that here the X (2) Toy Dept. and the100 (5) 1 Candy Dept. are 100 given a high rating of A.

Reason for rating Number

Example of Systematic Layout Planning: Reasons for Closeness

Code 1 2 3 4 Reason*
Type of customer Ease of supervision Common personnel Contact necessary

5
6

Share same price

Psychology

* Others may be used

Example of Systematic Layout Planning: Importance of Closeness

Value Closeness Line code Numerical weights

A
E I O U X

Absolutely necessary
Especially important Important Ordinary closeness OK Unimportant Undesirable

16
8 4 2 0 -16

Example of Systematic Layout Planning: Initial Relationship Diagram

1 I 2 I E 4 3 The number of lines here represent paths required to be taken in transactions between the departments. The more lines, the more the interaction between departments.

X
5

A Note here again, Depts. (1) and (2) are linked together, and Depts. (2) and (5) are linked together by multiple lines or required transactions.

Example of Systematic Layout Planning: Initial and Final Layouts

5 2 4 2
(400)

3 4
(100) (300)

5
(100)

1
(100) 50 ft

20 ft

Initial Layout
Ignoring space and building constraints

Final Layout
Adjusted by square footage and building size

Note in the Final Layout that Depts. (1) and (5) are not both placed directly next to Dept. (2).

Computerised Layout Planning

Construction Programmes
Computerised

Relationship Layout Planning

(CORELAP) Automated Layout Design Programme (ALDEP) Plant Layout Analysis and Evaluation Technique (PLANET)

Improvement Programmes
Computerised

Relative Allocation of Facilities Technique (CRAFT) Computerised Facilities Design (CFD)

Cellular Manufacturing Layouts

Operations required to produce a particular family (group) of parts are arranged in the sequence required to make that family Used when the operations system must handle a moderate variety of products in moderate volumes

Characteristics of Cellular Manufacturing Relative to Process Layouts

Equipment can be less general-purpose Material handling costs are reduced Training periods for operators are shortened In-process inventory is lower Parts can be made faster and shipped more quickly

Characteristics of Cellular Manufacturing Relative to Product Layouts

Equipment can be less special-purpose Changeovers are simplified Production is easier to automate

Manufacturing Cell: Benefits

1. Better human relations
2. Improved operator expertise 3. Less in-process inventory and material handling 4. Faster production setup

Manufacturing Cell: Transition from Process Layout

1. Grouping parts into families that follow a common sequence of steps
2. Identifying dominant flow patterns of parts families as a basis for location or relocation of processes 3. Physically grouping machines and processes into cells

Jumbled Flows in a Process Focused Shop

Lathe Milling Drilling

M Grinding

Assembly A A A

Receiving and shipping

Create Manufacturing Cells

Line flows in a job shop with three GT cells

L Cell 1

M
Cell 2 M

G A

Assembly area

Receiving

L Cell 3

Shipping

One Worker, Multiple Machines

Machine 1 Machine 2 Machine 3

Materials in Finished goods out Machine 5

Machine 4

Planning Cellular Manufacturing Layouts

Cell Formation Decision Which machines are assigned to manufacturing cells Which parts will be produced in each cell

Planning Cellular Manufacturing Layouts

Fundamental Requirements for Parts to be Made in Cells Demand for the parts must be high enough and stable enough that moderate batch sizes of the parts can be produced periodically. Parts must be capable of being grouped into parts families.

Planning Cellular Manufacturing Layouts

More-Complex Issues to be Resolved If all the parts cannot be cleanly divided between cells, how will we decide which are to be the exceptional parts? If inadequate capacity is available to produce all the parts in cells, which parts should be made outside the cells?

Planning Cellular Manufacturing Layouts

Cell Formation Procedure 1. Form the Parts-Machines Matrix. 2. Rearrange the Rows. Place the machines that produce the same parts in adjacent rows. 3. Rearrange the Columns. Place the parts requiring the same machines in adjacent columns. 4. Use the rearranged parts-machines matrix to identify cells, the machines for that cell and the parts that will be produced in that cell.

Example: Maxx Superchargers

Cell Formulation Maxx produces superchargers for high performance cars and trucks. Maxx has implemented a group technology program in its shop and now must formulate the manufacturing cells. Maxx has identified six parts that meet the requirements for CM. The parts-machines matrix on the next slide identifies the 6 parts and 5 machines on which the parts are presently produced.

Example: Maxx Superchargers

Cell Formulation Original Matrix

Parts
1 A B C D E X X 2 X X X X 3 X 4 X X X X 5 X X 6 X

Machines

Example: Maxx Superchargers

Cell Formulation Rows Rearranged

Parts
1
A E D C B

3 X X

5 X X

6 X X

Machines

X X

X X X

X X X

Example: Maxx Superchargers

Cell Formulation Columns Rearranged

Parts
A E D C B

3 X X

5 X X

6* X X

Machines

X X

X X X

X X

* exceptional part

Example: Maxx Superchargers

Cell Formulation Summary

2 manufacturing cells (MC1, MC2) will be used. Parts 3 and 5 will be produced in MC1 on machines A and E. Parts 1, 2 and 4 will be produced in MC2 on machines B, C and D. Part 6 is an exceptional part that cannot be produced within a single cell.

Planning Cellular Manufacturing Layouts Exercise

Machi nes
A B

Parts
1 2 X X X 3 4 5 6 7 X 8

C D E F G H I

X
X X X X X X X X

X
X X X X

Planning Cellular Manufacturing Layouts Exercise

Machi nes
B C

Parts
3 X X 5 X X 8 X 1 4 2 6* 7

F D G I A E H

X
X X X X X X X X

X X X X

Planning Cellular Manufacturing Layouts Exercise

Cell Formulation Summary

3 manufacturing cells (MC1, MC2, MC3) will be used. Parts 3, 5 and 8 will be produced in MC1 on machines B, C and F. Parts 1, and 4 will be produced in MC2 on machines D, G and I. Parts 2, 6 and 7 will be produced in MC3 on machines A, E and H. Part 6 is an exceptional part that cannot be produced within a single cell. A second machine F needs to be purchased or else it needs to be moved between MC1 and MC3.