05. facility layout
TRANSCRIPT
Facility LayoutConfiguration of departments, work centres and equipment, with particular emphasis on movement of work through the system
Two basic types of layout:
• Product• Process
• Require substantial investment of money & effort • Involve long term commitment• Have significant impact on the cost and efficiency of operations
Why Important?
Product Layout
The work is divided into a series of standardized tasks, permitting specialization of both labor and equipment
Facility Layout
Layout that uses standardized processing operations to achieve smooth, rapid, high volume flow
Advantages
• High rates of output• Low unit cost due to high volume • Low material handling cost per unit• High utilization of labor & equipment
Limitations
• Repetitive work – boring & fatigue• System is fairly inflexible• System is highly susceptible to breakdown
Facility Layout
U-shaped Layouts
• Compact• Increased communication• Flexibility in work
Facility Layout
Process LayoutDesigned to process items or provide services that involve a variety of processing requirements
Items are frequently moved in batches to the departments in a sequence that varies from job to job
Layout features functional grouping where similar kinds of activities are performed
X-ray ECG
PathologyUltrasound
Facility Layout
Advantages
• Can handle a variety of processing requirements • Not particularly vulnerable to equipment failures• General-purpose equipment is easier to maintain
Limitations
• High inventory costs for batch processing • Routing & scheduling pose continual challenges• Equipment utilization rates are low• Slow material handling –also inefficient
Facility Layout
X-ray ECG
PathologyUltrasound
Facility Layout
X-ray
ECG
Pathology
Ultrasound
Cell 1: X-ray, Ultrasound, Pathology Cell 2: X-ray, ECG Cell 3: Ultrasound, Pathology Cell 4: X-ray, ECG, Pathology
Cell 1 Cell 2
Cell 3 Cell 4
Cells are miniature versions of Product/Process layout
Groupings are determined by operations needed to perform work for a set of similar items
Facility Layout
Cell 1 Cell 2
Cell 4Cell 3
X-ray
ECG
Pathology
Ultrasound
Cellular LayoutMachines are grouped into cells
Fixed Position Layout
The items being worked on remains stationary, and workers, material and equipment are moved about
Facility Layout
Weight, size, bulk or some other factor makes it undesirable or extremely difficult to move the product
Facility LayoutLine Balancing
Assignment of work to stations in a line as to achieve the desired output rate with the smallest number of workstations
The goal is to obtain workstations with well-balanced workload
Facility LayoutSteps of Line Balancing
Determine desired output rate
Calculate Cycle Time
Find Theoretical Minimum
Determine Idle Time
Calculate Efficiency
Assign Tasks to Stations
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Station 1 Station 3Station 2 Station 4 Station 5
Facility Layout
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