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JTM3023: INDUSTRIAL
ENGINEERING
FACILITIES LAYOUT
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WHAT IS FACILITIES LAYOUT?
THE ARRANGEMENT OF MACHINES,
DEPARTMENTS, WORKSTATIONS,STORAGE AREAS, AISLES AND COMMON
AREAS WITHIN THE EXISTING OR
PROPOSED FACILITY.
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DISCUSSION 1
What type of layout(s) would be appropriate for:
a. Hospital
b. Electronic assembly
c. A university
d. Bank
e. Home constructionf. Airports
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OBJECTIVE OF LAYOUT
DECISIONS
TO ENSURE A SMOOTH FLOW OF WORK,
MATERIAL, PEOPLE AND INFORMATIONTHROUGH THE SYSTEM
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Good Layouts Consider
1. Mater ial handl ing equ ipment
2. Capaci ty and space requ irements
3. Env i ronment and aesthet ics
4. Flows of in format ion
5. Cost of mov ing between var iouswork areas
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Requires substantial investments ofmoney and effort
Involves long-term commitments
Has significant impact on cost andefficiency of short-term operations
Why layout decision is important?
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The Need for Layout Decisions
Inefficient operations
For Example:
High Cost
Bottlenecks
Changes in the design
of products or services
The introduction of new
products or services
Accidents
Safety hazards
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The Need for Layout Designs (Contd)
Changes inenvironmental
or other legal
requirements
Changes in volume of
output or mix of
products
Changes in methodsand equipment
Morale problems
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Patterns of flow
General flow pattern
(a) Straight
(b) U flow
(c) S flow
(d) L flow
(e) circular flow
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BASIC LAYOUTS
Process / Functional layouts
Product layouts / Assembly lines
Fixed position layouts
Cellular layouts
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PROCESS LAYOUTS
Group similar activities together in
departments or work centres according to the
process of function they perform
Job shops or batch productions
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Process Layout
Process Layout - work travels
to dedicated process centers
Milling
Assembly
& Test
Grinding
Drilling Plating
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Surgery
Radio logy
ERtr iageroom
ER Beds Pharmacy
Emergency room admiss ions
Bil l ing/exit
Laborator ies
Process-Oriented Layout
Patient A - bro ken leg
Patient B - errat ic h eartpacemaker
Figure 9.3
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PRODUCT LAYOUT
Arrange activities in a line according to the
sequence of operation that need to be
performed to assemble a particular product.
Mass production
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A Flow Line for Production or Service
Flow Shop or Assembly Line Work Flow
Raw
materials
or customer
Finished
item
Station
2
Station
3
Station
4
Materialand/or
labor
Statio
n
1
Materialand/or
labor
Materialand/or
labor
Materialand/or
labor
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A U-Shaped Production Line
1 2 3 4
5
6
78910
In
Out
Workers
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FIXED-POSITION LAYOUT
The items being worked on remains stationary.
Workers, materials and equipments are moved
about as needed.
Specialised for project production in which productproduced is too fragile, bulky or heavy to move.
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CELLULAR LAYOUTS
Group dissimilar machines into work centres
(called cells) that process families of parts
with similar shapes or processing
requirements.
Batch production
Simplify process layout
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Cellular Manufacturing Layout
-1111 -1111
222222222 - 2222
Assembly
3333333333 - 3333
44444444444444 - 4444
Lathe
Lathe
Mill
Mill
Mill
Mill
Drill
Drill
Drill
Heat
treat
Heat
treat
Heat
treat
Gear
cut
Gear
cut
Grind
Grind
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DISCUSSION 3
What type of layout(s) would be appropriate for:
a. Grocery store
b. Home construction
c. Electronic assembly
d. A university
e. Airport
f. Bank
g. Classroom
h. Parking lot
i. Human resources
departmentj. Office of product
designers
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Advantages and disadvantages
Fixedpositionlayout
Processlayout
Celllayout
Productlayout
Disadvantages
Advantages
Very high productand mix flexibility.
Product/customernot moved.
High variety oftasks for staff.
Very high unitcosts.
Scheduling spaceand activities canbe difficult.
High product andmix flexibility.
Relatively robustin the case ofdisruptions.
Easy to supervise.
Low utilization.
Can have very highwork in progress.
Complex flow.
Can give goodcompromise.
Fast throughput.
Group work canresult in goodmotivation.
Can be costly torearrange existing
layout.
Can need moreplant.
Low unit costs forhigh volume.
Opportunities forspecialization ofequipment.
Can have low mixflexibility.
Not very robust todisruption.
Work can be veryrepetitive.
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V olume-variety characteristics
Fixedposition layout
Process layout
Cell layout
Product layout
Low VOLUME High
Low
VARIET
Y
Low
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Design process Layout: RelationshipChart
Value Closeness
AAbsolutely
necessary
EEspecially
important
I Important
O Ordinary OK
U Unimportant
X Not desirable
President
Chief Techno logy Off icer
Engineers area
Secretary
Office entrance
Central fi les
Equipment cabinet
Photocop y equipment
Storage room
O
U
A
X
O
U
A
I
O
A
I
O
U
A
I
I
A
U
O
AU O
U
X
O I
U
OI
I
I
E
E
E
E E
1
2
3
4
5
6
7
8
9
Figure 9.1
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Relationship diagram -
Exercise
Meat Me, is a franchised chain of fast food burgerrestaurants. A new restaurant is being located in agrowing suburban community. Each restaurant hasthe following departments:
1. Cooking burgers
2. Cooking fries
3. Packing and storing burgers
4. Drink dispensers
5. Counter servers6. Drive-up server
Develop a relationship diagram of the restaurant.
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Design Product Layouts: Line
Balancing
Line Balancing is the process of
assigning
tasks to workstations in such a way that
the workstations have approximately
equal time requirements.
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Objectives
To obtain task grouping that represent
approximately equal time requirement.
To minimise idle time and bottleneck along
the line.
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Cycle Time
Cycle time is the maximum time
allowed at each workstation tocomplete its set of tasks on a unit.
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Assembly-Line Balancing
Object ive is to m inim ize the imbalance
between machines o r personnel wh i le
meet ing requi red ou tput
Starts w ith the precedencerelat ionships
1. Determ ine cyc le t ime
2. Calcu late theoret ical min imum number
of wo rkstat ions
3. Ba lance the l ine by ass ign ing spec i fi c
tasks to workstations
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Copier Example
This means that
tasks B and Ecannot be don eunt i l task A hasbeen com pleted
Performance Task Must Fol lowTime Task Lis ted
Task (m inu tes) Below
A 10
B 11 A
C 5 BD 4 B
E 12 A
F 3 C, D
G 7 F
H 11 EI 3 G, H
Total time66
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Copier Example
Performance Task Must Fol lowTime Task Lis ted
Task (m inu tes) Below
A 10
B 11 A
C 5 BD 4 B
E 12 A
F 3 C, D
G 7 F
H 11 EI 3 G, H
Total time66I
GF
C
D
H
B
E
A
10
1112
5
43
711 3
Figure 9.13
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I
GF
C
D
H
B
E
A
10
1112
5
43
711 3
Figure 9.13
Performance Task Must Fol lowTime Task Lis ted
Task (m inu tes) Below
A 10
B 11 A
C 5 BD 4 B
E 12 A
F 3 C, D
G 7 F
H 11 EI 3 G, H
Total time66
Copier Example
480 availablem ins per day
40 un its required
Cycle t ime =
Product ion t ime
available per day
Units required per day
= 480 / 40
= 12 minu tes per uni t
Min imumnumber of
workstat ions=
Time for task i
Cycle t ime
n
i = 1
= 66 / 12
= 5.5 or6 stat ions
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I
GF
C
D
H
B
E
A
10
1112
5
43
711 3
Figure 9.13
Performance Task Must Fol lowTime Task Lis ted
Task (m inu tes) Below
A 10
B 11 A
C 5 BD 4 B
E 12 A
F 3 C, D
G 7 F
H 11 EI 3 G, H
Total time66
Copier Example
480 availablem ins per day
40 un its required
Cycle t ime =12 mins
Min imum
workstat ions= 5.5 or6
Line-Balancing Heurist ics
1. Longest task time Choose the available task withthe longest task time
2. Most following tasks Choose the available task withthe largest number of followingtasks
3. Ranked positionalweight
Choose the available task forwhich the sum of following tasktimes is the longest
4. Shortest task time Choose the available task withthe shortest task time
5. Least number offollowing tasks
Choose the available task withthe least number of followingtasks
Table 9.4
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480 availablem ins per day
40 un its required
Cycle t ime =12 mins
Min imum
workstat ions= 5.5 or6
Performance Task Must Fol lowTime Task Lis ted
Task (m inu tes) Below
A 10
B 11 A
C 5 BD 4 B
E 12 A
F 3 C, D
G 7 F
H 11 EI 3 G, H
Total time66
Copier Example
I
GF
H
C
D
B
E
A
10 11
12
5
4
3 7
11
3
Station1
Station2
Stat ion3
Stat ion5
Stat ion 4
Stat ion 6
Figure 9.14
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Performance Task Must Fol lowTime Task Lis ted
Task (m inu tes) Below
A 10
B 11 A
C 5 BD 4 B
E 12 A
F 3 C, D
G 7 F
H 11 EI 3 G, H
Total time66
Copier Example
480 availablem ins per day
40 un its required
Cycle t ime =12 mins
Min imum
workstat ions= 5.5 or6
Eff ic iency = Task times
(actual num ber of works tat ion s) x ( largest cy cle t ime)
= 66 minutes/ (6 stat ions) x (12 minutes)
= 91.7%
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