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Technical Note 5
Facility Layout
OBJECTIVES
Facility Layout and Basic Formats Process Layout Layout Planning Assembly Line balancing Service Layout
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 The best locations for each department, where best means maximizing flow, which minimizing costs
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Determine
"Compare two departments at a time and exchange them if it reduces the total cost of the layout."
It does not guarantee an optimal solution CRAFT assumes the existence of variable path material handling equipment such as forklift trucks
Can be impractical to obtain Does not account for the qualitative factors that may be crucial to the placement decision Accounts for the importance of having each department located next to every other department Is also guided by trial and error
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Note here that the (1) Credit Dept. and (2) Toy Dept. are given a high rating of 6.
and the (5) 100 Candy Dept. are given a high rating of 6.
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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.
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4 Note in the Final Layout that Depts. (1) and (5) are not both placed directly next to Dept. (2).
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Initial Layout
Ignoring space and building constraints
Final Layout
Adjusted by square footage and building size
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Station 1
Station 2
Station 3
Minutes 7 3 6 per Unit Answer: The cycle time of the line is always determined by the work station taking the longest time. In this problem, the cycle time of the line is 7 minutes. There is also going to be idle time at the other two work stations.
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F
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C 3.25
D 1.2
E .5
Answer: Task C is the cycle time of the line and therefore, the maximum rate of production.
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Task A B C D E F G H
Description Assemble frame ount switch Assemble motor housing ount motor housing in frame Attach blade Assemble and attach safety grill Attach cord Test
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2 A
1 B
1 G
1.4 H F 1
C 3.25
D 1.2
E .5
Task A C D B E F G H
Followers 6 4 3 2 2 1 1 0
Station 1
Station 2
Station 3
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2 A
1 B
1 G
1.4 H F 1
C 3.25
D 1.2
E .5
Task A C D B E F G H
Followers 6 4 3 2 2 1 1 0
Station 2
Station 3
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2 A
1 B
1 G
1.4 H F 1
C 3.25
D 1.2
E .5
Task A C D B E F G H
Followers 6 4 3 2 2 1 1 0
Station 2
Station 3
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2 A
1 B
1 G
1.4 H F 1
C 3.25
D 1.2
E .5
Task A C D B E F G H
Followers 6 4 3 2 2 1 1 0
Station 2
Station 3
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2 A
1 B
1 G
1.4 H F 1
C 3.25
D 1.2
E .5
Task A C D B E F G H
Followers 6 4 3 2 2 1 1 0
Station 3
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2 A
1 B
1 G
1.4 H F 1
C 3.25
D 1.2
E .5
Task A C D B E F G H
Followers 6 4 3 2 2 1 1 0
Station 3
Idle
.95
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2 A
1 B
1 G
1.4 H F 1
C 3.25
D 1.2
E .5
Task A C D B E F G H
Followers 6 4 3 2 2 1 1 0
Station 3 D (4.2-1.2) 3
Idle
.95
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2 A
1 B
1 G
1.4 H F 1
C 3.25
D 1.2
E .5
Task A C D B E F G H
Followers 6 4 3 2 2 1 1 0
Idle
.95
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2 A
1 B
1 G
1.4 H F 1
C 3.25
D 1.2
E .5
Task A C D B E F G H
Followers 6 4 3 2 2 1 1 0
Idle
.95
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2 A
1 B
1 G
1.4 H F 1
C 3.25
D 1.2
E .5
Task A C D B E F G H
Followers 6 4 3 2 2 1 1 0
Idle
.95
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Question: What are our primary considerations for a fixed position layout?
Answer: Arranging materials and equipment concentrically around the production point in their order of use.
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