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Chapter 2Chapter 2Chapter 2Chapter 2Chapter 2Chapter 2Chapter 2Chapter 2
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Facilities
Planning
Facilities
Location
StructuralDesign
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Facilities
Design
Layout
Design
Handling SystemDesign
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Developing a facilities layout is a critical stepin the facilities planning process.
Industrial engineer must be CREATIVE and
alternatives.
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What is Layout : the configuration of departments, work centers,
and equipment, with particular emphasis onmovement of work (customers or materials)
through the system.
In this chapter, scope of Facilities Layout according toindustrial and manufacturing field.
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1. Use workers and space efficiently2. Avoid bottlenecks among process3. Minimize production time or customer
service time
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4. Minimize unnecessary material handlingcosts
5. Eliminate unnecessary movement ofworkers or materials
6. Design for safety
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Inefficient operations
For Example:
High Cost
Changes in the design
of products or services
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Bottlenecks
The introduction of newproducts or services
Accidents
Safety hazards
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Changes in
environmentalor other legal
Changes in volume ofoutput or mix of
products
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Changes in methodsand equipment
Morale problems
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Layout design is effected by:
Centralized vs. Decentralize Storage ofWIP, Tooling, & Supplies
Fixed Path vs. Variable Path Handling
n t oa ze Degree of Automation
Type and Level of Inventory and
Control of Materials
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Product layout Layout that uses standardized processing
operations to achieve smooth, rapid, high-volumeflow
Layout that can handle varied processing
requirements
Fixed Position layout Layout in which the product or project remains
stationary, and workers, materials, and equipmentare moved as needed
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Found in continuous production line flow ofrepetitive assembly or process
Suitable to produce high-volume quantity, highlystandardized products or repetitive processes.
In a product layout, resources are arranged
sequentially, based on the routing of the products.
E.g Production assembly for car, electronic device,circuit board
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Standardized product
High production volume Stable production quantities
Uniform quality of raw materials &componen s
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Lower variable cost perLower variable cost per
unitunit Lower material handlingLower material handling
costscosts
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Lower workLower work--inin--processprocessinventories (WIP)inventories (WIP)
Easier training &Easier training &
supervisionsupervision Rapid throughputRapid throughput
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Higher capitalHigher capitalinvestmentinvestment
S ecial e ui mentS ecial e ui ment
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Any work stoppageAny work stoppagestops whole processstops whole process
Lack of flexibilityLack of flexibility
VolumeVolume
ProductProduct
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A type of facility layout in which the floorplan is arranged with similar processes or
machines located together according to itsfunction.
For example, a machine shop with millslocated together, lathes located together,saws located together, and so on, is arrangedwith a process layout.
E.g Garment manufacturing, Car Workshop
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Non-Standardized product, varies type
Medium rate production volume Variable production quantities
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Flexibility. The firm has the ability to handle a variety ofprocessing requirements.
Motivation. Employees in this type of layout willprobably be able to perform a variety of tasks onmultiple machines, as opposed to the boredom of
. A process layout also allows the employer to use some
type of individual incentive system.
System protection. Since there are multiple machines
available, process layouts are not particularly vulnerableto equipment failures.
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E.R.Triage
room
Patient B - erratic
acemaker
Patient A -
broken leg
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E.R. beds Pharmacy Billing/exit
Hallway
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Utilization. Equipment utilization rates in processlayout are frequently very low, because machine
usage is dependent upon a variety of outputrequirements.
Cost. , . Material handling is slower and more inefficient. The span of supervision is small due to job complexities
(routing, setups, etc.), so supervisory costs are higher. Other department like accounting, inventory control, and
purchasing usually are highly involved.
Confusion. Constantly changing schedules androutings make juggling process requirements moredifficult.
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Fixed Position Layout: Layout in which theproduct or project remains stationary, andworkers, materials, and equipment are
.
Large construction projects e.g Aircraft &Ship manufacturing
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In order to make this work, required resourcesmust be portable so that they can be taken to the
job for "on the spot" performance.
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