Process Selection and Facility Layout Chap 6 Part b

1

Facilities Layout

Layout: the configuration of departments, work centers, and equipment, with particular emphasis on movement of work (customers or materials) through the system

6-2

Objective of Layout Design1. 2. 3. 4. 5. 6. 7.

Facilitate attainment of product or service quality Use workers and space efficiently Avoid bottlenecks Minimize unnecessary material handling costs Eliminate unnecessary movement of workers or materials Minimize production time or customer service time Design for safety6-3

The Need for Layout DecisionsInefficient operationsFor Example:

High Cost Bottlenecks Changes in environmental or other legal requirements6-4

Changes in products/services Changes in methods and equipmentAvailability of new technology Safety hazards

Basic Layout Types

Product layouts Process layouts Fixed-Position layout Combination layouts---example: cellular layout

6-5

Basic Layout Types

Product layoutLayout that uses standardized processing operations to achieve smooth, rapid, highvolume flow

Process layoutLayout that can handle varied processing requirements

Fixed Position layoutLayout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed6-6

Product LayoutProduct layout: uses standardized processing operations to achieve smooth, rapid, high-volume flow

Raw materials or customerMaterial and/or labor

Station 1

Station 2

Station 3

Station 4

Finished item

Material and/or labor

Material and/or labor

Material and/or labor

Used for Repetitive or Continuous Processing

6-7

Advantages of Product Layout?

Disadvantages of Product Layout?

6-8

A U-Shaped Production LineFigure 6.6 In

1

2

3

4 5

Workers

6Out

10

9

8

7

6-9

Process Layouts (Functional layouts)

ExampleMilling Assembly & Test Grinding

Drilling

Plating

Different products may present quite different processing requirements and sequences of operations.6-10

Comparison of Product and Process LayoutsProduct Layout (sequential) Used for repetitive processing: Repetitive or ContinuousWork Station 1 Work Station 2 Work Station 3

Process Layout (functional) Used for intermittent Processing: Job Shop or Batch

Dept. A

Dept. B

Dept. C

Dept. D

6-11

Advantages of Process Layouts?

Disadvantages of Process Layouts?

6-12

Fixed Position LayoutsFixed Position Layout: Layout in which the product or project remains stationary, and workers, materials, and equipment are moved as needed. Nature of the product dictates this type of layout

Weight Size Bulk

6-13

Cellular Layouts

Cellular ProductionLayout in which machines are grouped into a cell that can process items that have similar processing requirements

Group TechnologyThe grouping into part families of items with similar design or manufacturing characteristics

6-14

Cellular Manufacturing Layout-1111 Lathe Mill Drill Heat treat Heat treat Heat treat Drill Gear cut -1111

222222222

3333333333

Lathe

Mill

Grind - 3333

44444444444444

Mill

Gear cut

- 4444

Part families

111111 222222 333333 444444

6-15

Assembly

Mill

Drill

Grind - 2222

Functional vs. Cellular LayoutsTable 6.3 DimensionNumber of moves between departments Travel distances Travel paths Job waiting times Throughput time Amount of work in process Supervision difficulty Scheduling complexity Equipment utilization

Functionalmany longer variable greater higher higher higher higher lower6-16

Cellularfew shorter fixed shorter lower lower lower lower higher

6-16

Service LayoutsWarehouse and storage layouts Retail layouts Office layouts Service layouts must be aesthetically pleasing as well as functional

6-17

True or False?1. Process layouts allow greater flexibility in processing than product layouts.

18

True or False?2. Process layouts tend to have low inprocess inventories.

19

True or False?3.Product layouts can more easily adapt to variations in product requirements than process layouts can.

20

True or False?4. Process layouts feature departments or other functional groupings of personnel or equipment.

21

True or False?5. The design of service layouts, e.g., warehouse and supermarket layouts, focuses on cost minimization and product flow.

22