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To Accompany Russell and Taylor, Operations Management, 4th Edition, 2003 Prentice-Hall, Inc. All rights reserved.

ChapterChapter55

FacilitiesFacilities



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Objectives of Facility LayoutObjectives of Facility Layout Minimize material handling costsMinimize material handling costs

Utilize space efficientlyUtilize space efficiently

Utilize labor efficientlyUtilize labor efficiently

Eliminate bottlenecksEliminate bottlenecks

Facilitate communication and interactionFacilitate communication and interactionbetween workers, between workers andbetween workers, between workers andtheir supervisors, or between workers andtheir supervisors, or between workers and

customerscustomers Reduce manufacturing cycle time or

customer service time


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Objectives of Facility LayoutObjectives of Facility Layout Eliminate waste or redundant movementEliminate waste or redundant movement

Facilitate the entry, exit, and placement ofFacilitate the entry, exit, and placement ofmaterial, products, or peoplematerial, products, or people

Incorporate safety and security measuresIncorporate safety and security measures

Promote product and service qualityPromote product and service quality

Encourage proper maintenance activitiesEncourage proper maintenance activities

Provide a visual control of operations orProvide a visual control of operations or

activitiesactivities Provide flexibility to adapt to changingProvide flexibility to adapt to changing

conditionsconditions

Increase capacityIncrease capacity


4/81To Accompany Russell and Taylor, Operations Management, 4th Edition, 2003 Prentice-Hall, Inc. All rights reserved.

Basic Types of LayoutsBasic Types of Layouts

Process LayoutProcess Layout Machines grouped by process they performMachines grouped by process they perform

Product LayoutProduct Layout

Linear arrangement of workstations toLinear arrangement of workstations toproduce a specific productproduce a specific product

Fixed Position LayoutFixed Position Layout

Used in projects where the product cannotUsed in projects where the product cannot

be movedbe moved



Process Layout in ServicesProcess Layout in Services



Process Layout in ServicesProcess Layout in Services

Womenslingerie

Womensdresses

Womenssportswear

Shoes

Cosmeticsand jewelry

Entry anddisplay area

Housewares

Childrensdepartment

Mensdepartment

FigureFigure 5.15.1



Manufacturing Process LayoutManufacturing Process Layout

L

L

L

L

L

L

L

L

L

LM

M

M

M

D

D

D

D

D

D

D

D

G

G

G

G

G

G

A A AReceiving andShipping

Assembly

Painting Department

Lathe DepartmentMilling

Department Drilling Department

GrindingDepartment

P

P

FigureFigure 5.25.2




L

L

L

L

L

L

L

L

L

LM

M

M

M

D

D

D

D

D

D

D

D

G

G

G

G

G

G


Assembly

Painting Department



GrindingDepartment

P

P

FigureFigure 5.25.2


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L

L

L

L

L

L

L

L

L

LM

M

M

M

D

D

D

D

D

D

D

D

G

G

G

G

G

G


Assembly

Painting Department



GrindingDepartment

P

P

FigureFigure 5.25.2


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A Product LayoutA Product Layout


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Comparison Of ProductComparison Of Product

And Process LayoutsAnd Process Layouts

11.. DescriptionDescription Sequential arrangementSequential arrangement Functional groupingFunctional grouping

of machinesof machines of machinesof machines

22.. Type of ProcessType of Process Continuous, massContinuous, mass Intermittent, job shopIntermittent, job shop

production, mainlyproduction, mainly batch production,batch production,assemblyassembly mainly fabricationmainly fabrication

33.. ProductProduct StandardizedStandardized Varied,Varied,

made to stockmade to stock made to ordermade to order

44.. DemandDemand StableStable FluctuatingFluctuating55.. VolumeVolume HighHigh LowLow

66.. EquipmentEquipment Special purposeSpecial purpose General purposeGeneral purpose

77.. WorkersWorkers Limited skillsLimited skills Varied skills

PRODUCT LAYOUTPRODUCT LAYOUT PROCESS LAYOUTPROCESS LAYOUT

Varied skills

TableTable 5.15.1


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Comparison Of ProductComparison Of Product

And Process LayoutsAnd Process Layouts

88.. InventoryInventory Low inLow in--process,process, High inHigh in--process,process,

high finished goodshigh finished goods low finished goodslow finished goods

99.. Storage spaceStorage space SmallSmall LargeLarge

1010.. MaterialMaterial Fixed pathFixed path Variable pathVariable pathhandlinghandling ((conveyorconveyor)) ((forkliftforklift))

1111.. AislesAisles NarrowNarrow WideWide

1212.. SchedulingScheduling Part of balancingPart of balancing DynamicDynamic

1313.. Layout decisionLayout decision Line balancingLine balancing Machine locationMachine location1414.. GoalGoal Equalize work atEqualize work at Minimize materialMinimize material

each stationeach station handling costhandling cost

1515.. AdvantageAdvantage EfficiencyEfficiency Flexibility

PRODUCT LAYOUTPRODUCT LAYOUT PROCESS LAYOUTPROCESS LAYOUT

Flexibility

TableTable 5.15.1


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FixedFixed--Position LayoutsPosition Layouts

Typical of projectsTypical of projectsEquipment, workers, materials, otherEquipment, workers, materials, other

resources brought to the siteresources brought to the siteHighly skilled laborHighly skilled labor

Often low fixedOften low fixed

Typically high variable costsTypically high variable costs


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Designing Process LayoutsDesigning Process Layouts

Minimize material handlingMinimize material handlingcostscosts

Block DiagrammingBlock Diagramming

Minimize nonadjacent loadsMinimize nonadjacent loads Use when quantitative dataUse when quantitative data

is availableis available

Relationship DiagrammingRelationship Diagramming Based on location preference between areasBased on location preference between areas

Use when quantitative data is not availableUse when quantitative data is not available


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Block DiagrammingBlock Diagramming

Create load summary chartCreate load summary chartCalculate compositeCalculate composite((two waytwo way))

movementsmovements

Develop trial layouts minimizingDevelop trial layouts minimizing

number of nonadjacent loadsnumber of nonadjacent loads


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Process LayoutProcess Layout


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Process LayoutProcess LayoutExampleExample 5.15.1

DepartmentDepartment 11 22 33 44 55

Load Summary ChartLoad Summary Chart

FROMFROM//TOTO DEPARTMENTDEPARTMENT

11 100100 5050

22 200200 505033 6060 4040 5050

44 100100 6060

55 5050


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Process LayoutProcess Layout

DepartmentDepartment 11 22 33 44 55

Load Summary ChartLoad Summary Chart

FROMFROM//TOTO DEPARTMENTDEPARTMENT

11 100100 5050

22

200200 505033 6060 4040 5050

44 100100 6060

55 5050

ExampleExample 5.15.1

Composite Movements Composite Movements

2 3 200 loads 3 5 50 loads2 4 150 loads 2 5 50 loads1 3 110 loads 3 4 40 loads1 2 100 loads 1 4 0 loads

4 5 60 loads 1 5 0 loads

1 2

3

4

5

100

200

150

50

50 6040110

Grid 2


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Relationship DiagrammingRelationship Diagramming

Used when quantitativeUsed when quantitativedata is not availabledata is not available

MutherMuthers grid displayss grid displayspreferencespreferences

Denote locationDenote location

preferences withpreferences with

weighted linesweighted lines


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Relationship DiagramsRelationship Diagrams


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Relationship DiagramsRelationship Diagrams((aa)) Relationship diagram of original layoutRelationship diagram of original layout

OfficesOffices

StockroomStockroom

LockerLockerroomroom

ToolroomToolroom

ShippingShippingandand

receivingreceiving

ProductionProduction

FigureFigure 5.65.6

KeyKey:: AAEE

II

OO

UU

XX


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Relationship DiagramsRelationship Diagrams((bb)) Relationship diagram of revised layoutRelationship diagram of revised layout

OfficesOffices

StockroomStockroom

LockerLockerroomroom

ToolroomToolroom

ShippingShipping

andandreceivingreceiving

ProductionProduction KeyKey:: AAEE

II

OO

UU

XXFigureFigure 5.65.6


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Line BalancingLine BalancingPrecedence diagramPrecedence diagram

Network showing orderNetwork showing order

of tasks and restrictionsof tasks and restrictions

on their performanceon their performanceCycle timeCycle time

Maximum time productMaximum time product

spends at any onespends at any one

workstationworkstation


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Efficiency of LineEfficiency of Line

ii

ii == 11

ttii

nCnCaaEE ==

ii

ii == 11

ttii

CCddNN==

EfficiencyEfficiencyMinimum numberMinimum number

of workstationsof workstations

wherewhere

ttii == completion time for elementcompletion time for element iijj == number of work elementsnumber of work elements

nn == actual number of workstationsactual number of workstations

CCaa == actual cycle timeactual cycle time

CCdd == desired cycle timedesired cycle time


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Line Balancing ProcessLine Balancing Process11.. Draw and label a precedence diagramDraw and label a precedence diagram..

22

.

.Calculate the desired cycle time required for theCalculate the desired cycle time required for thelineline..

33.. Calculate the theoreticalCalculate the theoreticalminimum number of workstationsminimum number of workstations..

44.. Group elements into workstations,Group elements into workstations,recognizing cycle time andrecognizing cycle time andprecedence constraintsprecedence constraints..

55.. Calculate the efficiency of the lineCalculate the efficiency of the line..66.. Stop if theoretical minimum number ofStop if theoretical minimum number of

workstations on an acceptable efficiency levelworkstations on an acceptable efficiency levelreachedreached.. If not, go back to stepIf not, go back to step44..


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Line BalancingLine BalancingWORK ELEMENTWORK ELEMENT PRECEDENCEPRECEDENCE TIMETIME ((MINMIN))

AA Press out sheet of fruitPress out sheet of fruit 0.10.1

BB Cut into stripsCut into strips AA 0.20.2

CC Outline fun shapesOutline fun shapes AA 0.40.4

DD Roll up and packageRoll up and package B, CB, C 0.30.3

0.10.1

0.20.2

0.40.4

0.30.3D

B

C

A


Cd = = = 0.4 minute40 hours x 60 minutes / hour

6,000 units

2400

6000

N= = = 2.5 workstations1.0

0.4

0.1 + 0.2 + 0.3 + 0.4

0.4


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Line BalancingLine BalancingREMAINING REMAININGWORKSTATION ELEMENT TIME ELEMENTS

CCdd == 0.40.4

NN== 2.52.5

0.10.1

0.20.2

0.40.4

0.30.3D

B

C

A



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Line BalancingLine Balancing

0.10.1

0.20.2

0.40.4

0.30.3D

B

C

A


CCdd == 0.40.4

NN== 2.52.5

REMAINING REMAININGWORKSTATION ELEMENT TIME ELEMENTS

1 A 0.3 B, CB 0.1 C, D


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0.10.1

0.20.2

0.40.4

0.30.3D

B

C

A


CCdd == 0.40.4

NN== 2.52.5


1 A 0.3 B, CB 0.1 C, D

2 C 0.0 D3 D 0.1 none


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0.10.1

0.20.2

0.40.4

0.30.3D

B

C

A


CCdd == 0.40.4

NN== 2.52.5


1 A 0.3 B, CB 0.1 C, D

2 C 0.0 D3 D 0.1 none

A, B C D

Workstation 1

Workstation 2

Workstation 3

0.3minute

0.4minute

0.3minute


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Computerized LineComputerized Line


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Computerized LineComputerized LineBalancingBalancing

Use heuristics to assign tasks toUse heuristics to assign tasks toworkstationsworkstations

Ranked positional weightRanked positional weight

Longest operation timeLongest operation time

Shortest operation timeShortest operation time

Most number of following tasksMost number of following tasks Least number of following tasksLeast number of following tasks


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Hybrid LayoutsHybrid LayoutsCellular layoutsCellular layouts

Group machines into machining cellsGroup machines into machining cells

Flexible manufacturing systemsFlexible manufacturing systems

Automated machining & materialAutomated machining & materialhandling systemshandling systems

MixedMixed--model assembly linesmodel assembly lines Produce variety of models on one lineProduce variety of models on one line


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Cellular LayoutsCellular Layouts1.1. Identify families of parts withIdentify families of parts with

similar flow pathssimilar flow paths2.2. Group machines into cellsGroup machines into cells

based on part familiesbased on part families

3.3. Arrange cells so materialArrange cells so material

movement is minimizedmovement is minimized

4.4. Locate large shared machinesLocate large shared machinesat point of useat point of use


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Parts FamiliesParts Families


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Original Process LayoutOriginal Process Layout


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CA B Raw materials

Assembly

1

2

3

4

5

6 7

8

9

10

11

12

FigureFigure 5.85.8

Part Routing MatrixPart Routing Matrix


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Part Routing MatrixPart Routing Matrix

Machines

Parts 1 2 3 4 5 6 7 8 9 10 11 12

A x x x x x

B x x x x

C x x xD x x x x x

E x x x

F x x xG x x x x

H x x x

FigureFigure 5.85.8

Revised Cellular Layout


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Revised Cellular LayoutRevised Cellular Layout

Revised Cellular Layout


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Revised Cellular LayoutRevised Cellular Layout

3

6

9

Assembly

12

4

8 10

5

7

11

12

A B C

Raw materials

Cell 1 Cell 2 Cell 3

FigureFigure 5.95.9


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Advantages OfAdvantages Of


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gg

Cellular LayoutsCellular Layouts

Reduced material handling and transit timeReduced material handling and transit time Reduced setup timeReduced setup time

Reduced workReduced work--inin--

process inventoryprocess inventory

Better use of humanBetter use of human

resourcesresources Easier to controlEasier to control

Easier to automateEasier to automate

Disadvantages OfDisadvantages Of


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Cellular LayoutsCellular Layouts

Inadequate part familiesInadequate part familiesPoorly balanced cellsPoorly balanced cells

Expanded trainingExpanded trainingand schedulingand scheduling

of workersof workers

Increased capitalIncreased capital

investmentinvestment


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AutomatedAutomated


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ManufacturingManufacturingCellCell


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Flexible ManufacturingFlexible Manufacturing


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e b e a u actu ggSystemsSystems

Automated machining operationsAutomated machining operations Automated material handlingAutomated material handling

Automated tool changersAutomated tool changers

Computer controlled systemComputer controlled system

Designed around size of parts processedDesigned around size of parts processed

& average processing time for parts& average processing time for parts

Can process wide variety of items quicklyCan process wide variety of items quickly


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FMS LayoutsFMS Layouts


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yy

FigureFigure 5.125.12


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Mixed ModelMixed Model


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Assembly LinesAssembly Lines

Produce multiple models in anyProduce multiple models in anyorder on one assembly lineorder on one assembly line

Issues in mixed model linesIssues in mixed model lines Line balancingLine balancing

UU--shaped lineshaped line

Flexible workforceFlexible workforce

Model sequencingModel sequencing

Balancing UBalancing U--Shaped LinesShaped Lines


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A B C

D E

Precedence diagramPrecedence diagram::

Cycle timeCycle time == 1212 minmin




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A B C

D E

A,B C,D E



((aa)) Balanced for a straight lineBalanced for a straight line

99 minmin 1212 minmin 33 minmin

EfficiencyEfficiency

= = = .= = = .

66666666

==

66.766.7

%%

2424

3636

2424

33((1212))




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A B C

D E

A,B C,D E

C,D

A,B

E



((aa)) Balanced for a straight lineBalanced for a straight line ((bb)) Balanced for a UBalanced for a U--shaped lineshaped line

99 minmin 1212 minmin 33 minmin

EfficiencyEfficiency

= = = .= = = .

66666666

==

66.766.7

%%

2424

3636

2424

33((1212))

1212 minmin 1212 minminEfficiencyEfficiency = = == = = 100100 %%2424

2424

2424

22((1212))FigureFigure 5.135.13

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