dd dd gg gg gg mm mm mm aa aa l ll ll ll l layout

D D

D D

G G

G G

G G

M M

M M

M M

A A

A A

L

L L

L L

L L

L

LayoutLayout

What Is Layout What Is Layout Planning?Planning?

• What centres should the layout include?

• How much space and capacity does each centre need?

• How should each centre’s space be

configured?

• Where should each centre be located?

Strategic IssuesStrategic Issues

• Facilitating the flow of materials

• Increasing the efficient utilization of labour and equipment

• Increasing customer convenience

• Reducing hazards to workers

• Improving employee morale

• Improving communication

Criteria for a Good Criteria for a Good LayoutLayout• Maximum flexibility• Maximum co-ordination• Maximum use of volume• Maximum visibility• Maximum accessibility

Criteria for a Good Criteria for a Good LayoutLayout• Minimum distance• Minimum handling• Minimum discomfort• Inherent safety• Maximum security• Efficient material flow• Identification

Layout TypesLayout Types

• Process Layout

• Product Layout

• Fixed-Position Layout

• Hybrid Layout - Cells

Layout Types - Process Layout Types - Process LayoutLayout


Organizes resources around the process and groups work stations or departments according to function

Intermittent, low volume, high-variety


FoundryMilling

machines

LathesGrinding

Painting Drills

Office

Welding

Forging

(a) Layout of a job shop



FoundryMilling

machines

LathesGrinding

Painting Drills

Office

Welding

Forging


Advantages

General purpose, flexible resources are less capital intensive

Less vulnerable to changes in product mix or new market strategies

Equipment utilization can be higher, because not dedicated to one product line

Employee supervision can be more specialized


Disadvantages

– Slower processing rates

– Lost production time during setups

– More capital and more floor space tied up with inventory

– Longer manufacturing lead times

– Costly materials handling, requiring variable path devices

– Production planning and control more difficult


A major challenge in designing process layouts is to identify dominant flow patterns among the jumbled traffic and to locate centres so that materials handling is minimized.

Layout Types - Product Layout Types - Product LayoutLayout


Dedicates resources to a product or closely related product family

Repetitive, high-volume, continuous production

Workstations or departments are arranged in a linear path, which is consistent with the routing sequence of the product.


(b) Layout of a production line

Station 1 Station 2 Station 3 Station 4


Station 1 Station 2 Station 3 Station 4

(b) Layout of a production line


Advantages

Faster processing rates

Lower inventories

Infrequent setups


Disadvantages

– More risk of layout redesign

– Less flexible

– For low volume, dedicated resources have low utilization


Challenge in designing product layouts

– Minimize resources used to achieve desired output rate

– Balance tasks, equalize the workload assigned to resources

Layout Types - Layout Types - Fixed-position LayoutFixed-position Layout


Product is fixed in place. Resources come to the product, minimizing number of times product must be moved.

Used for:

Very large products, ships, roads, power plants, airplanes

Service of fragile or bulky items


Product

Process Process

ProcessProcess

Process


• Advantages

– Material movement is reduced to a minimum.

– The task is usually carried out by a gang of operators, hence continuity of operators and responsibility is required.

– Production centres often operate independently of each other, and effective scheduling can be planned to ensure minimum total production time.


• Limitations

– Movement of machines and equipment to the production centre may be costly and time consuming.

– Positioning of the material or object or machines may be cumbersome and costly.

– Machine and equipment utilisation is usually low, owing to handling and positioning time.

– High grades of skill are required.

Muther’s P-Q ChartMuther’s P-Q Chart

Group Group TechnologyTechnology


Machine 1

Machine 2

Machine 3

Machine 4Machine

5

Materials in

Finished goods out

One Worker, Multiple MachinesOne Worker, Multiple Machines


Parts FamiliesParts Families

Source: Mikell P. Groover. Automation, Production Systems, and Computer-Aided Manufacturing. Englewood Cliffs, NJ: Prentice-Hall, 1980, p. 540. Used by permission.


Drilling

D D

D D

Grinding

G G

G G

G G

Milling

M M

M M

M M

Assembly

A A

A A

Lathing

Receiving and shipping

L

L L

L L

L L

L


(a) Jumbled flows in a job shop without GT cells

Drilling

D D

D D

Grinding

G G

G G

G G

Milling

M M

M M

M M

Assembly

A A

A A

Lathing

Receiving and shipping

L

L L

L L

L L

L


(b) Line flows in a job shop with three GT cells

Cell 3

L M G G

Cell 1 Cell 2

Assembly area

A A

L M DL

L MShipping

D

Receiving

G

Longhorn Longhorn MachineMachine

60'

90'

Longhorn Longhorn MachineMachine Department Area Needed(ft2)

1 Burr and grind 10002 NC equipment 9503 Shipping and receiving 7504 Lathes and drills 12005 Tool crib 8006 Inspection 700

Total 5400

60'

90'

2 4 3

6 5 1

Longhorn Longhorn MachineMachine Department Area Needed(ft2)

1 Burr and grind 10002 NC equipment 9503 Shipping and receiving 7504 Lathes and drills 12005 Tool crib 8006 Inspection 700

Total 5400

Figure 10.6

60'

90'

2 4 3

6 5 1


60'

90'

2 4 3

6 5 1


Trips Between Departments

Department 1 2 3 4 5 6

1 Burr and grind —

2 NC equipment —

3 Shipping and receiving —

4 Lathes and drills —

5 Tool crib —

6 Inspection —

60'

90'

2 4 3

6 5 1




1 Burr and grind — 20 20 80

2 NC equipment — 10 75

3 Shipping and receiving — 15 90

4 Lathes and drills — 70

5 Tool crib —

6 Inspection —

60'

90'

2 4 3

6 5 1


60'

90'

2 4 3

6 5 1

Longhorn Longhorn MachineMachine Closeness Rating Between Departments



2 NC equipment —



5 Tool crib —

6 Inspection —

60'

90'

2 4 3

6 5 1




2 NC equipment —



5 Tool crib —

6 Inspection —

Closeness Rating

Rating Definition

A Absolutely necessaryE Especially importantI ImportantO Ordinary closenessU UnimportantX Undesirable

60'

90'

2 4 3

6 5 1



1 Burr and grind — E U I U A

2 NC equipment — O U E I

3 Shipping and receiving — O U A

4 Lathes and drills — E X

5 Tool crib — U

6 Inspection —

Closeness Rating

Rating Definition

A Absolutely necessaryE Especially importantI ImportantO Ordinary closenessU UnimportantX Undesirable

60'

90'

2 4 3

6 5 1



1 Burr and grind — E U I U A

2 NC equipment — O U E I

3 Shipping and receiving — O U A

4 Lathes and drills — E X

5 Tool crib — U

6 Inspection —

Explanation Codes

Code Meaning

1 Materials handling2 Shared personnel3 Ease of supervision4 Space utilization5 Noise6 Employee attitudes

60'

90'

2 4 3

6 5 1



1 Burr and grind — E U I U A(3, 1) (2, 1) (1)

2 NC equipment — O U E I(1) (1) (6)

3 Shipping and receiving — O U A(1) (1)

4 Lathes and drills — E X(1) (5)

5 Tool crib — U

6 Inspection —

Explanation Codes

Code Meaning

1 Materials handling2 Shared personnel3 Ease of supervision4 Space utilization5 Noise6 Employee attitudes

60'

90'

2 4 3

6 5 1


60'

90'

2 4 3

6 5 1


60'

90'

2 4 3

6 5 1

Departments 3 and 6 close together Departments 1 and 6 close together Departments 2 and 5 close together Departments 4 and 5 close together

Figure 10.6

60'

90'

2 4 3

6 5 1


60'

90'

4 3


Example 10.1

60'

90'

2 4 3

6 5 1


60'

90'

4 3


6

Example 10.1

60'

90'

2 4 3

6 5 1


60'

90'

4 3


61

Example 10.1

60'

90'

2 4 3

6 5 1


60'

90'

4 3


61

5

2

Example 10.1

60'

90'

2 4 3

6 5 1


60'

90'

4 3


61

5

2

Figure 10.7

60'

90'

2 4 3

6 5 1


60'

90'

2 4 3

6 5 1




1 Burr and grind — 20 20 80

2 NC equipment — 10 75

3 Shipping and receiving — 15 90

4 Lathes and drills — 70

5 Tool crib —

6 Inspection —

Example 10.2

60'

90'

2 4 3

6 5 1


Load Distance Analysis

Current Plan Proposed Plan

Dept Closeness Distance DistancePair Factor, l d ld Score d ld Score

1,2 201,4 201,6 802,3 102,5 753,4 153,6 904,5 70

Example 10.2

60'

90'

2 4 3

6 5 1





1,2 20 31,4 20 21,6 80 22,3 10 22,5 75 23,4 15 13,6 90 34,5 70 1

Example 10.2

60'

90'

2 4 3

6 5 1





1,2 20 3 601,4 20 2 401,6 80 2 1602,3 10 2 202,5 75 2 1503,4 15 1 153,6 90 3 2704,5 70 1 70

ld =785

Example 10.2

60'

90'

2 4 3

6 5 1





1,2 20 3 60 1 201,4 20 2 40 1 201,6 80 2 160 1 802,3 10 2 20 3 302,5 75 2 150 1 753,4 15 1 15 1 153,6 90 3 270 1 904,5 70 1 70 1 70

ld =785 ld = 400

Example 10.2

A-1 Distribution A-1 Distribution SystemsSystems


Figure 10.8

Dock Aisle

Storage area

Storage area


Trips to and Area NeededDepartment from Dock (blocks)

1. Toasters 280 12. Air conditioners 160 23. Microwaves 360 14. Stereos 375 35. TVs 800 46. Radios 150 17. Bulk storage 100 2

Example 10.3

Dock Aisle

Storage area

Storage area


Trips to and Area NeededDepartment from Dock (blocks) Ratio Rank

1. Toasters 280 1 280/1 = 2802. Air conditioners 160 2 160/2 = 803. Microwaves 360 1 360/1 = 3604. Stereos 375 3 375/3 = 1255. TVs 800 4 800/4 = 2006. Radios 150 1 150/1 = 1507. Bulk storage 100 2 100/2 = 50

Example 10.3

Dock Aisle

Storage area

Storage area



1. Toasters 280 1 280/1 = 280 22. Air conditioners 160 2 160/2 = 80 63. Microwaves 360 1 360/1 = 360 14. Stereos 375 3 375/3 = 125 55. TVs 800 4 800/4 = 200 36. Radios 150 1 150/1 = 150 47. Bulk storage 100 2 100/2 = 50 7

Example 10.3

Dock Aisle

Storage area

Storage area




Example 10.3

Dock Aisle

Storage area

3

Storage area




Example 10.3

Dock Aisle

Storage area

3

1

Storage area




Example 10.3

Dock Aisle

Storage area

3

1

5 5

5 5

Storage area




Figure 10.9

Dock Aisle

Storage area

3

1

5 5

5 5

6 4 2 7

4 4 2 7

Storage area

Zone SystemsZone Systems


Shipping doors

Tractor trailer

Tractor trailer

Zones Zones

Figure 10.10


Click to add titleZones Zones

Shipping doors

Tractor trailer

Tractor trailer

Feeder lines

Feeder lines

Figure 10.10


Click to add titleZones Zones Control

station Shipping doors

Tractor trailer

Tractor trailer

Feeder lines

Feeder lines

Figure 10.10


Click to add titleZones Zones Trunk lineControl

station Shipping doors

Tractor trailer

Tractor trailer

Overflow

Feeder lines

Feeder lines

Figure 10.10

Addison Wesley Addison Wesley Longman Distribution Longman Distribution CenterCenter

Line BalancingLine Balancing

Green Grass, Inc.Big Broadcaster

Line BalancingLine BalancingBig Broadcaster


A Bolt leg frame to hopper 40 NoneB Insert impeller shaft 30 AC Attach axle 50 AD Attach agitator 40 BE Attach drive wheel 6 BF Attach free wheel 25 CG Mount lower post 15 CH Attach controls 20 D, EI Mount nameplate 18 F, G

Total 244

Work Time ImmediateElement Description (sec) Predecessor(s)

Example 10.4



Total 244


40

A

Example 10.4



Total 244


40

30

B

A

Example 10.4



Total 244


40

50

B

C

A

30

Example 10.4



Total 244


40

50

30

40

D

B

C

A

Example 10.4



Total 244


40

6

50

E30

40

D

B

C

A

Example 10.4



Total 244


40

6

50

E30

25

40

D

B

FC

A

Example 10.4



Total 244


40

6

50

15

E30

25

40

D

B

FC

A

G

Example 10.4



Total 244


40

6

20

50

15

E30

25

40H

D

B

FC

A

G

Example 10.4



Total 244


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G

Example 10.4


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G

Figure 10.11


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G

Desired output rate = 2400/weekPlant operates 40 hours/week

Example 10.5


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G


r = 2400/40 = 60 units/hour

Example 10.5


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G


r = 2400/40 = 60 units/hour

c = 1/60 = 1 minute/unit= 60 seconds/unit

Example 10.5


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G


c = 60 seconds/unit

Example 10.5


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G


c = 60 seconds/unit

TM = 244 seconds/60 seconds= 4.067 or 5 stations

Example 10.5


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G


TM = 244 seconds/60 seconds= 4.067 or 5 stations

Efficiency = [244\5(60)]100 = 81.3%

c = 60 seconds/unit

Example 10.5


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G

c = 60 seconds/unitTM = 5 stationsEfficiency = 81.3%

Example 10.6


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G


Cumm IdleStation Candidate Choice Time Time

Example 10.6


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G



S1 A A 40 20

Example 10.6


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G



S1 A A 40 20

S1

Example 10.6


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G



S1 A A 40 20

S2 B,C C 50 10

S1

Example 10.6


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G



S1 A A 40 20

S2 B,C C 50 10

S1

S2

Example 10.6


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G



S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30

S1

S2

Example 10.6


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G



S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30E,F,G F 55 5

S1

S2

Example 10.6


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G



S1 A A 40 20

S2 B,C C 50 10

S3 B,F,G B 30 30E,F,G F 55 5

S1

S2S3

Example 10.6


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G


S1

S2S3

Example 10.6


40

6

20

50

15

18

E30

25

40H

I

D

B

FC

A

G


S1

S2S3

S5S4

Figure 10.12

dd dd gg gg gg mm mm mm aa aa l ll ll ll l layout

Documents

position layout slide

layout planning

risk of layout redesign

difficult slide

specialized slide

communication slide

production line slide

job shop slide