facilities layout (september 2014)
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Facilities Layout
Industrial Management 1
Industrial Management 1
Prepared by:Industrial Systems Engineering Research Group
Universiti Tun Hussein Onn Malaysia
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Learning Objectives
List some reasons for layoutsdesign
Describe the basic layout types List the advantages and
disadvantages of layout designs.
Develop simple process layouts(using computer software)
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Layout: the conguration of departments,work centers, and euipment, withparticular emphasis on movement of work(customers or materials) through thesystem.
!roduct layouts
!rocess layouts
"i#ed$!osition layout
%ombination layouts
Facilities Layout
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Objective of Layout
Design&. "acilitate attainment of product or service
uality
'. se workers and space eciently
*. +void bottlenecks
. -inimie unnecessary material handlingcosts
/. 0liminate unnecessary movement ofworkers or materials
1. -inimie production time or customerservice time
2. Design for safety
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Inefficient operations
For Example:
High CostBottlenecks
Changes in the design
of products or services
The introduction of newproducts or services
Accidents
afet! ha"ards
The Need for Layout
Design
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Changes in
environmental
or other legalre#uirements
Changes in volume of
output or mix of
products
Changes in methodsand e#uipment
$orale pro%lems
The Need for LayoutDesign (Contd)
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!roduct layout tilies standardied processing
operations to achieve smooth, rapid,high$volume 3ow
!rocess layout+ble to handle variety process
reuirements
"i#ed !osition layout!roduct (or pro4ect) remains stationary,
whereas workers$materials$euipment
Basic Layout
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Raw materials
or customer
Finished
itemStation
2
Station
2
Station
3
Station
3
Station
4
Station
4
Material
and/or
labor
Station
1
Material
and/or
labor
Material
and/or
labor
Material
and/or
labor
Used for Repetitive or Continuous Processing
Product Layout(seuential)Utilizesstandardized process operations to achieve smooth, rapid,
high-volume flow
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5igh volume production (high prod6nrate)
Low cost per unit product Low cost in material handling
5igh utiliation of labour$euipment Labour specialiation (specic works)
0stablished routing and scheduling
+dvantages of !roduct
Layout
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7epetitive 4obs
Low skill workers may not maintain uality
of output (impair uality) 8ot 3e#ible to change in volume.
9mpair output rate when breakdown(shutdown)
!reventive maintenance is critical.
Disadvantages of !roductLayout
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Dept. A
(Stamping)
Dept. B
(Lathe)
Dept. D
(Grinding)
Dept. C
(Milling)
Dept. F
(Coating)
Dept. E
(Etching)
Used for Intermittent processing
Job Sop or B!tc Processes
Process Layout (functional)
rocess Layout
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Process Layout+ble to handle variety of process reuirements
Used for Intermittent processing
Job Sop or B!tc Processes
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+ble to handle variety of processreuirements.
8ot aected production rate when machinefailures.
Low cost in euipment utiliation.
!ossible to create individual (worker)incentive plans
+dvantages of !rocessLayouts
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9n$process inventory costs can be high
%hallenging routing and scheduling
0uipment utiliation rates are low -aterial handling slow and inecient
%omple#ities often reduce span of
supervision ;pecial attention for each product or
customer
+ccounting and purchasing are more
involved
Disadvantages of !rocessLayouts
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Large construction project (in real world)
Fixed Position Laout
(!imulation)
Fixed Position Layout
"ature of product#& $eight& !ize& %ul&
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1 2 3 4
5
6
7891
In
Out
Workers
$;haped !roduction Line
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%ellular !roduction Layout in which machines are
grouped into a cell that canprocess items that have similarprocessing reuirements
=roup >echnology>he grouping into part families
of items with similar design ormanufacturing characteristics
Cellular Layouts
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'hroughput time higher lo&er
+mount of work inprocess
higher lo&er
;upervisiondiculty
higher lo&er
;cheduling
comple#ity
higher lo&er
Table 6!
"unctional vs. %ellularLayouts