10 Facility Layout-Process_PKB

8/12/2019 10 Facility Layout-Process_PKB

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FACILITY LAYOUT

Process Layout


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Facility Layout

A Layout problem may be to

determine the location for a new machine,

develop a new layout for an existingproduction plant,

develop a layout for a new production

plant,

etc.


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Facility Layout

Facility layout can be defined as the processby which the placement of departments,workgroups within departments,workstations, machines, and stock-holdingpoints within a facility are determined.


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A Layout problem may arise due to changes in the design of a product,

addition or deletion of a product,

change in the demand of a product, changes in the design of the process,

addition or deletion of a process,

obsolescence/replacement of equipment,

frequent accidents,

changes in legal/environmental regulations,

competitive cost reduction, etc.

Facility Layout


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Objectives of Facility Layout

Reduce congestion that impedes movement of peopleor material

Minimize material handling costs

Provide safety and comfort to employees

Utilize labour efficiently Increase morale

Utilize available space effectively and efficiently

Provide ease of supervision

Facilitate co-ordination and face-to-face communication

Minimize investment in equipment

Minimize production time

Maintain flexibility of arrangement and operation


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Basic Layout Types

Product or Line Layouts - uses standardizedprocessing operations to achieve smooth,high-volume flow

Process or Functional Layouts - can handlevaried processing requirements

Project or Fixed-Position - the product orproject remains stationary, and workers,materials, and equipment are moved as needed

Cellular Layouts

Combination Layouts


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Process Layout: Interdepartmental Flow

GivenThe flow (number of moves) to and from all

departments

The cost of moving from one department to

another

The existing or planned physical layout of the

plant

DetermineThe best locations for each department,

where best means maximizing flow, while

minimizing costs


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Graphic Approaches to Layout

Planning

1 2

5

3

64Facility Outline Locations


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Planning

From

No. of Moves to

A B C D E F

A - 7 - - - 5B - - - 4 10 -

C - 7 - - 2 -

D - - 8 - - -E 4 - - - - 3

F - 6 - - 10 -

From-To or Travel Chart


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Planning

Deptt. A B C D E FNo. oflinks

3 5 3 2 5 4


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Planning

Deptt. A B C D E FNo. oflinks

3 5 3 2 5 4

Number of Links or Number of Moves?


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Planning

A 7

F

B D

E C10

4

2

5 10 8

6

7

4

3


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Planning

A B

E

D

CFA Possible Facility Layout


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Process Layout: Systematic LayoutPlanning

Numerical flow of items between workcentres

Can be impractical to obtain

Does not account for the qualitative factors that may

be crucial to the placement decision

Systematic Layout Planning

Accounts for the importance of having each

department located next to every other department Is also guided by trial and error

Switching workcentres then checking the resultsof the closeness score


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Muthers

SystematicLayout

Planning

Input Data and

Activities

1. Flow of Materials2. Activity

Relationships

3. Relationship Chart

4. Relationship

Diagram

5. Space Requirement 6. Space Available

7. Space Relationship

Diagram

8. ModifyingConsiderations 9. PracticalLimitations

10. Develop

Alternative Layouts

11. Evaluation


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Example of Systematic Layout Planning:

Relating Reasons and Importance

From

1. Credit department

2. Toy department

3. Wine department

4. Camera department

5. Candy department

6

I

--

U

4

E

--

U

--

U

1

I

1,6

A

--

U

1

X

1

X

To2 3 4 5

Area

(sq. ft.)

100

400

300

100

100

Closeness rating

Reason for rating

Letter

Number

Relationship Chart or REL Chart


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Relating Reasons and Importance

From

1. Credit department

2. Toy department

3. Wine department

4. Camera department

5. Candy department

6

I

--

U

4

A

--

U

--

U

1

I

1,6

A

--

U

1

X

1

X

To2 3 4 5

Area

(sq. ft.)

100

400

300

100

100

Closeness rating

Reason for rating

Note here

that the (1)

Credit Dept.

and (4)

CameraDept. are

given a high

rating of A.Letter

Number

Note here that

the (2) Toy Dept.

and the (5)Candy Dept. are

given a high

rating of A.


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Reasons for Closeness

Code

1

2

3

4

5

6

Reason*

Type of customer

Ease of supervision

Common personnel

Contact necessary

Share same price

Psychology

* Others may be used


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Example of Systematic Layout Planning:Initial Relationship Diagram

1

2

4

3

5

X X

E

A

I

The number of lines

here represent paths

required to be taken in

transactions between

the departments. The

more lines, the more

the interaction betweendepartments.

Note here again, Depts. (1) and(2) are linked together, and

Depts. (2) and (5) are linked

together by multiple lines or

required transactions.

I


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Initial and Final Layouts

1

2 4

3

5

Initial Layout

Ignoring space and

building constraints

2(400)

5(100) 1(100) 4(100)

3

(300)

50 ft

20 ft

Final Layout

Adjusted by square

footage and building

size

Note in the

Final Layout

that Depts.

(1) and (5)are not both

placed

directly next

to Dept. (2).


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Computerised Layout Planning

Construction ProgrammesComputerised Relationship Layout Planning

(CORELAP)

Automated Layout Design Programme (ALDEP) Plant Layout Analysis and Evaluation Technique

(PLANET)

Improvement ProgrammesComputerised Relative Allocation of FacilitiesTechnique (CRAFT)

Computerised Facilities Design (CFD)


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Cellular Manufacturing Layouts

Operations required to produce a particularfamily (group) of parts are arranged in thesequence required to make that family

Used when the operations system must handle amoderate variety of products in moderatevolumes


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Characteristics of Cellular Manufacturing

Relative to Process Layouts

Equipment can be less general-purpose

Material handling costs are reducedTraining periods for operators are shortened

In-process inventory is lower

Parts can be made faster and shipped morequickly


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Characteristics of Cellular Manufacturing

Relative to Product Layouts

Equipment can be less special-purpose

Changeovers are simplified Production is easier to automate


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Manufacturing Cell:Benefits

1. Better human relations

2. Improved operator expertise

3. Less in-process inventory and material

handling

4. Faster production setup


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Manufacturing Cell:

Transition from Process Layout

1. Grouping parts into families that follow acommon sequence of steps

2. Identifying dominant flow patterns of partsfamilies as a basis for location or relocationof processes

3. Physically grouping machines and processesinto cells


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Cell 3

L M G G

Cell 1 Cell 2

Assembly

areaA A

L M DL

L MShipping

D

Receiving

G

Create Manufacturing Cells

Line flows in a job shop with three GT cells


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One Worker, Multiple Machines

Materials in

Machine

2Machine

1

Machine

5

Finished

goods out

Machine

4

Machine

3


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Planning Cellular Manufacturing

Layouts

Cell Formation Decision

Which machines are assigned tomanufacturing cells

Which parts will be produced in each cell


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Layouts

Fundamental Requirements for Parts to beMade in Cells

Demand for the parts must be high enoughand stable enough that moderate batch sizesof the parts can be produced periodically.

Parts must be capable of being grouped intoparts families.


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Layouts

More-Complex Issues to be Resolved

If all the parts cannot be cleanly divided

between cells, how will we decide which are tobe the exceptional parts?

If inadequate capacity is available to produce all

the parts in cells, which parts should be madeoutside the cells?


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LayoutsCell Formation Procedure

1. Form the Parts-Machines Matrix.2. Rearrange the Rows.

Place the machines that produce the sameparts in adjacent rows.

3. Rearrange the Columns.

Place the parts requiring the same machinesin adjacent columns.4. Use the rearranged parts-machines matrix to

identify cells, the machines for that cell and the

parts that will be produced in that cell.


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Example: Maxx Superchargers

Cell Formulation

Maxx produces superchargers for highperformance cars and trucks. Maxx hasimplemented a group technology program in itsshop and now must formulate themanufacturing cells. Maxx has identified six

parts that meet the requirements for CM.The parts-machines matrix on the next slide

identifies the 6 parts and 5 machines on which

the parts are presently produced.


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Cell FormulationOriginal Matrix

1 2 3 4 5 6X X X

X X X X

X X

X XX X X

A

B

C

DE

Parts

Machines


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Cell FormulationRows Rearranged

1 2 3 4 5 6

X X XX X X

X X

X X

X X X X

AE

D

C

B

Parts

Machines


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Cell FormulationColumns Rearranged

3 5 6* 1 2 4

X X XX X X

X X

X X

X X X X

AE

D

C

B

Parts

Machines

* exceptional part


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Cell FormulationSummary

2 manufacturing cells (MC1, MC2) will be used.

Parts 3 and 5 will be produced in MC1 on machinesA and E.

Parts 1, 2 and 4 will be produced in MC2 onmachines B, C and D.

Part 6 is an exceptional part that cannot be producedwithin a single cell.


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LayoutsExerciseMachi

nesParts

1 2 3 4 5 6 7 8

A X X

B X XC X X X

D X X

E X X

F X X X

G X

H X X X

I X X

l i C ll l f i


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Machines

Parts

3 5 8 1 4 2 6* 7

B X X

C X X XF X X X

D X X

G X

I X X

A X X

E X X

H X X X


LayoutsExercise

Pl i C ll l M f i


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Cell FormulationSummary

3 manufacturing cells (MC1, MC2, MC3) will be used.

Parts 3, 5 and 8 will be produced in MC1 on machines B, C

and F. Parts 1, and 4 will be produced in MC2 on machines D, G

and I.

Parts 2, 6 and 7 will be produced in MC3 on machines A, Eand H.

Part 6 is an exceptional part that cannot be produced within asingle cell.

A second machine F needs to be purchased or else it needs tobe moved between MC1 and MC3.


LayoutsExercise

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10 Facility Layout-Process_PKB

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