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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
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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
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Process Layout in ServicesProcess Layout in Services
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Process Layout in ServicesProcess Layout in Services
Womenslingerie
Womensdresses
Womenssportswear
Shoes
Cosmeticsand jewelry
Entry anddisplay area
Housewares
Childrensdepartment
Mensdepartment
FigureFigure 5.15.1
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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
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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
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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
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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
ExampleExample 5.25.2
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
ExampleExample 5.25.2
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Line BalancingLine Balancing
0.10.1
0.20.2
0.40.4
0.30.3D
B
C
A
ExampleExample 5.25.2
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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Line BalancingLine Balancing
0.10.1
0.20.2
0.40.4
0.30.3D
B
C
A
ExampleExample 5.25.2
CCdd == 0.40.4
NN== 2.52.5
REMAINING REMAININGWORKSTATION ELEMENT TIME ELEMENTS
1 A 0.3 B, CB 0.1 C, D
2 C 0.0 D3 D 0.1 none
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Line BalancingLine Balancing
0.10.1
0.20.2
0.40.4
0.30.3D
B
C
A
ExampleExample 5.25.2
CCdd == 0.40.4
NN== 2.52.5
REMAINING REMAININGWORKSTATION ELEMENT TIME ELEMENTS
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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Original Process LayoutOriginal Process Layout
Original Process LayoutOriginal Process Layout
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Original Process LayoutOriginal Process Layout
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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gg
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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Balancing UBalancing U--Shaped LinesShaped Lines
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A B C
D E
Precedence diagramPrecedence diagram::
Cycle timeCycle time == 1212 minmin
FigureFigure 5.135.13
Balancing UBalancing U--Shaped LinesShaped Lines
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A B C
D E
A,B C,D E
Precedence diagramPrecedence diagram::
Cycle timeCycle time == 1212 minmin
((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))
FigureFigure 5.135.13
Balancing UBalancing U--Shaped LinesShaped Lines
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A B C
D E
A,B C,D E
C,D
A,B
E
Precedence diagramPrecedence diagram::
Cycle timeCycle time == 1212 minmin
((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