facility layout
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Facility Layout
1WK4-Facility Layout
OutlineOutline
• Objectives of Facility Layout
• Types of Layouts– Fixed Position Layout– Process Layout– Product Layout
• Designing Facility Layouts
2WK4-Facility Layout
World Class Factory• Physical factory in the manufacturing industry making
saleable products. • Indicators of excellence in factory operations:Defect-free : a conventional factory has 5% defect rates, a WCF
should have 98% less defects or better. Six-sigma WCF’s can achieve 3-4 dpm.
Fast : in terms of manufacturing lead time or turnaround time, or order processing time for make-to-order factories.
Flexible : more product variety and models, factories with highly flexible and adaptive manufacturing systems
Lean : With extremely high productivity and yield, it dramatically reduces inventories, space, machines, and even people and suppliers required to achieve the production target.
Environment-friendly. : Green manufacturing
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Focused Plant Layout
• Process focus• Product focus• Quality focus• Customer (Quick response) focus• Supplier focus• Operating cost focus• Productivity focus• Flexibility focus• Logistics focus
General Objectives of LayoutsGeneral Objectives of Layouts
Develop an economical layout which will meet the requirements of:
product design and volume (product strategy)
process equipment and capacity (process strategy)
quality of work life (human resource strategy)
building and site constraints (location strategy)
5WK4-Facility Layout
Basic Types of LayoutsBasic Types of Layouts• Fixed Position (project) Layout
–used in projects where the product cannot be moved
• Process Layout–machines, people, or equipment grouped by process they perform
• Product Layout–linear arrangement of workstations to produce a specific product or service
6WK4-Facility Layout
Product family
Process department 7WK4-Facility Layout
Production line
Fixed materials location
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Factors Complicating a Fixed Factors Complicating a Fixed Position LayoutPosition Layout
There is limited space at virtually all sites
At different stages in the construction process, different materials are needed – therefore, different items become critical as the project develops
The volume of materials needed is dynamic
9WK4-Facility Layout
Designing a Designing a Fixed Position LayoutFixed Position Layout
Building construction, Ship, Airplane, etc.• There are no hard and fast rules -- probably
because the problem is ill - defined.• Most attention is paid to scheduling and
sequencing of tasks in a project.• However, critical issues remain regarding
time & space requirements for materials, equipment, labor, etc
10WK4-Facility Layout
ProcessProcess Layout: Manufacturing Layout: Manufacturing
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A A AReceiving andShipping Assembly
Painting Department
Lathe DepartmentMilling
Department Drilling Department
Grinding Department
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A A ProductProduct Layout Layout
IN
OUT
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Compare & Contrast Compare & Contrast ProductProduct & & ProcessProcess Layouts Layouts
PRODUCT LAYOUT PROCESS LAYOUT
1. Description Sequential arrangement Functional grouping
of equipment, people of machines, people, tasks
2. Type of Process Continuous, mass Intermittent, job shop
production, mainly batch production,
assembly mainly fabrication
3. Product Standardized, often Varied, frequently
made to stock made to order
4. Demand Stable Fluctuating
5. Volume High Low
6. Equipment Special purpose General purpose
7. Workers Limited skills Varied skills
13WK4-Facility Layout
Compare & Contrast Compare & Contrast ProductProduct & & ProcessProcess Layouts Layouts
PRODUCT LAYOUT PROCESS LAYOUT
8. Inventory Low in-process, High in-process,
high finished goods low finished goods
9. Storage space Small Large
10. Material Fixed path Variable path
handling (conveyor) (forklift)
11. Aisles Narrow Wide
12. Scheduling Part of balancing Dynamic
13. Layout decision Line balancing Machine location
14. Goal Equalize work at Minimize material
each station handling cost
15. Advantage Efficiency Flexibility
14WK4-Facility Layout
Layout Design: Systematic Layout Layout Design: Systematic Layout PlanningPlanning
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Systematic Layout Planning - 26
Muther’s Systematic
Layout Planning
Procedure
Systematic Layout Planning - 27
Systematic Layout Planning Procedure
Information Gathering PQRST items
Product: what is to be produced Quantity: volume to be produced Routing: how it is to be produced Support services: with what will we produce Timing/Transport: when to produce and how to move parts in & out
Quantity & Variety often dictate the layout type (product/process, etc.) can be used to determine
o which products justify their own lines,o which families justify their own cells.
Systematic Layout Planning - 28
Photographs about the product “Exploded” drawings Engineering drawings of individual parts Parts list Bill of materials (structure of product) Assembly chart Route sheet Operations process chart Etc.
Systematic Layout Planning Procedure
Information Gathering
Systematic Layout Planning - 29
Systematic Layout Planning ProcedureInformation Gathering
Systematic Layout Planning - 30
Schedule design decisions tell us how much to produce and when to produce.
Market Forecast
Number of Machines
Production Demand
Production Rate
Product Mix+
Production Rate
Continuous orIntermittent Production
Systematic Layout Planning ProcedureInformation Gathering
Systematic Layout Planning - 31
Systematic Layout Planning Procedure
Flow Analysis and Activity Analysis
Flow analysisFlow analysis concentrates on some quantitativequantitative measure of movement between departments or activities
Activity analysisActivity analysis is primarily concerned with the non-quantitativenon-quantitative factors that influence the location of departments or activities
Charts and diagrams useful in flow analysisCharts and diagrams useful in flow analysis:- Flow process chart- Multi-product process charts- Flow diagram- From-to-charts
Systematic Layout Planning - 32
Systematic Layout Planning Systematic Layout Planning ProcedureProcedureFlow and Activity Analysis - A1Flow and Activity Analysis - A1
Systematic Layout Planning - 33
Systematic Layout Planning Systematic Layout Planning ProcedureProcedureFlow and Activity Analysis A-2Flow and Activity Analysis A-2
Systematic Layout Planning - 34
Desirability (or lack) of locating two work-centers together• information that is difficult to quantify• (example 1) shipping & receiving - share common facilities (e.g., loading docks)• (example 2) engineering & purchasing - efficient communication, quality, • (example 3) environmental factors - delicate testing vs. vibration
Summarized in a relationship or REL chart
Systematic Layout Planning Systematic Layout Planning ProcedureProcedureFlow and Activity AnalysisFlow and Activity Analysis
Systematic Layout Planning - 35
Code Reason
1 Frequency of use high
2 Frequency of use medium
3 Frequency of use low
4 Information flow high
5 Information flow medium
6 Information flow low
Rating Definition
A Absolutely Necessary
E Especially Important
I Important
O Ordinary Closeness OK
U Unimportant
X Undesirable
1. Directors conference room
2. President
3. Sales department
4. Personnel
5. Plant manager
6. Plant engineering office
7. Production supervisor
8. Controller office
9. Purchasing department
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Activity Relationship ChartActivity Relationship Chart
Systematic Layout Planning Systematic Layout Planning ProcedureProcedureFlow and Activity AnalysisFlow and Activity Analysis
Systematic Layout Planning - 36
Code
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Reason
Type of customer
Ease of supervision
Common personnel
Contact necessary
Share same price
Psychology
Systematic Layout Planning Systematic Layout Planning Procedure Procedure Activity Relationship ChartActivity Relationship Chart
Activity Relationship ChartActivity Relationship Chart
Systematic Layout Planning - 37
Value
A
E
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ClosenessLinecode
Numericalweights
Absolutely necessary
Especially important
Important
Ordinary closeness OK
Unimportant
Undesirable
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8
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0
-80
Systematic Layout Planning Systematic Layout Planning Procedure Procedure Relationship DiagramRelationship Diagram
Systematic Layout Planning - 38
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U U
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The number of lines here represent paths required to be taken in transactions between the departments. The more lines, the more the interaction between departments.
The number of lines here represent paths required to be taken in transactions between the departments. The more lines, the more the interaction between departments. Note here again, Depts. (1) and
(2) are linked together, and Depts. (2) and (5) are linked together by multiple lines or required transactions.
Note here again, Depts. (1) and (2) are linked together, and Depts. (2) and (5) are linked together by multiple lines or required transactions.
Systematic Layout Planning Systematic Layout Planning Procedure Procedure Relationship Diagram Relationship Diagram (or Activity Relationship (or Activity Relationship
Diagram)Diagram)
Systematic Layout Planning - 39
Code Reason
1 Flow of material
2 Ease of supervision
3 Common personnel
4 Contact Necessary
5 Conveniences
Rating Definition
A Absolutely Necessary
E Especially Important
I Important
O Ordinary Closeness OK
U Unimportant
X Undesirable
1. Offices
2. Foreman
3. Conference Room
4. Parcel Post
5. Parts Shipment
6. Repair and Service Parts
7. Service Areas
8. Receiving
9. Testing
10. General Storage
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Systematic Layout Planning Systematic Layout Planning Procedure Procedure Activity Relationship ChartActivity Relationship Chart
Systematic Layout Planning - 40
10
5 8 7
9 6
4 2 3
1
Systematic Layout Planning Systematic Layout Planning Procedure Procedure Relationship DiagramRelationship Diagram
The Relationship DiagramRelationship Diagram positions activities spatially. Proximities are typically used to reflect the relationship between pairs of activities
Systematic Layout Planning - 41
Muther’s Systematic
Layout Planning Procedure
Based on the input data and an understanding of the roles and relationship between activities, a material flow analysis (from-to-chart) and an activity relationship analysis (activity relationship chart) are performed.
From the analysis performed, a relationship diagram is developed.
Systematic Layout Planning - 42
Production-center method
Converting method – the present space requirements are converted to those required for the proposed layout
Roughed-out layout method – using templates or models on the layout to obtain an estimate of configuration and space requirements
Ratio trend projection method – for general space requirements e.g. square feet per direct labor hour, square feet per unit produced, etc.
Space DeterminationSpace Determination
Systematic Layout Planning Systematic Layout Planning ProcedureProcedure
Systematic Layout Planning - 43
• Raw material storage• In-process inventory
storage• Finished-goods storage• Aisles, cross isles, and
main aisles• Receiving and shipping• Material handling
equipment storage• Tool rooms and tool cribs• Maintenance• Packaging
Space DeterminationSpace Determination
• Quality control and inspection
• Supervision• Health and medical
facilities• Food service• Lavatories, washrooms,
etc.• Offices• Employee and visitor
parking• Receiving and shipping
parking• Other storage
Systematic Layout Planning Systematic Layout Planning ProcedureProcedure
Systematic Layout Planning - 44
Muther’s Systematic
Layout Planning
Procedure
Systematic Layout Planning - 45
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5 8 7
9 6
4 2 3
1
Systematic Layout Planning Systematic Layout Planning Procedure Procedure Relationship DiagramRelationship Diagram
Systematic Layout Planning - 46
2(125)
3(125)
1(1000)
4(350)
3(125)
6(75)
9(500)
10(1750)
5(500)
8(200)
7(575)
Systematic Layout Planning Systematic Layout Planning Procedure Procedure Space Relationship DiagramSpace Relationship Diagram
Systematic Layout Planning - 47
Relationship diagram:all departments are of equal size.
Space Relationship diagram:templates proportional in size to departmental space requirement
Systematic Layout Planning Systematic Layout Planning ProcedureProcedure
Systematic Layout Planning - 48
Relationship diagram
Activity Relations and Relationship Diagram – Another example
Systematic Layout Planning Systematic Layout Planning ProcedureProcedure
Systematic Layout Planning - 49
Space relationship diagram
Systematic Layout Planning Systematic Layout Planning ProcedureProcedure
Systematic Layout Planning - 50
Alternative block layout
Systematic Layout Planning Systematic Layout Planning ProcedureProcedure
Systematic Layout Planning - 51
Modifying considerations and limitationsModifying considerations and limitations
Site-specific and Operation-specific conditionspossible adjustment to the layout
Example: Location of external transportation system (e.g., rail, road,
river access) → may restrict the location of shipping and receiving
limitations on access to utilities (HVAC, lighting, etc) in certain areas
aisles should be straight and close to the point where move requests are generated without obstructing manufacturing activities
Systematic Layout Planning Systematic Layout Planning ProcedureProcedure
Systematic Layout Planning - 52
Muther’s Systematic
Layout Planning
Procedure
Systematic Layout Planning - 53
EvaluationEvaluation
Factor-analysis method (evaluating the layout alternatives) List all of the factors to be considered important Weight the relative importance of each of these factors to
each other Rate the alternative plans against one factor at a time Calculate the weighted rating values and sum up those
values to obtain the total value for each of the alternatives Select the alternative with the highest total value
FactorsCost, flexibility, maintainability, expandability (modularity),
safety, operation ease
Systematic Layout Planning Systematic Layout Planning ProcedureProcedure
Systematic Layout Planning - 54
Area Space needs (ft2)• Branch manager 200• Head teller 150• Teller counter/break room 600• New accounts clerk 100• Loan officers 200• Customer waiting room/lounge 150• Lobby 500
Branch Bank Example
Systematic Layout Planning Systematic Layout Planning Procedure Procedure Example B – Page 1Example B – Page 1
Systematic Layout Planning - 55
1. Branch Manager
2. Head Teller
3. Teller Counter/ Break Room
4. New Accounts Clerk
5. Loan Officer
6. Customer Lounge/ Break Room
1100I
100U
1000I
2400E
1600E
800I
400O
3000
100U 300
O
200O
800I
50U70
U
50U
Note: Lobby to be central to all
Note: Lobby to be central to all
Steps 1 & 2:Work flows and REL chart
Steps 1 & 2:Work flows and REL chart
Systematic Layout Planning Systematic Layout Planning Procedure Procedure Example B – Page 2Example B – Page 2
Systematic Layout Planning - 56
3 2
4 1
6 5
KeyAE IOU
Step 3:ArrangeWork Areas
7 To all
7
Systematic Layout Planning Systematic Layout Planning Procedure Procedure Example B – Page 3Example B – Page 3
Systematic Layout Planning - 57
5
600 ft 2 150 ft 2
200 ft 2
200 ft 2
Step 4:Space Arrangement
3 2
1
6150 ft
2
100 ft24
7500 ft
2
Systematic Layout Planning Systematic Layout Planning Procedure Procedure Example B – Page 4Example B – Page 4
Systematic Layout Planning - 58
12-8
3 2
4
1
65
600 ft2
100 ft2
150 ft2
156 ft2
228 ft2
216 ft2
Lobby450 ft
2
100
ft2
Entry
50’
40’
Step 5:Floor Plan 7
Systematic Layout Planning Systematic Layout Planning Procedure Procedure Example B – Page 5Example B – Page 5
Example - SLP
• Four departments are to be located in a building of 600x1000 ft. The expected personnel flows and are requirement for departments are shown in the table below. Develop a block layout using SLP.
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Block Layout using Graph Theory
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Relationship (REL) Graph
• Given a (block) layout with M activities, a corresponding planar undirected graph, called the Relationship (REL) Graph, can always be constructed.
REL Graph
1 2
543
6(Exterior)
1 2
543
Block Layout
• A REL graph has M+1 nodes (one node for each activity and a node for the exterior of the layout. The exterior can be considered as an additional activity. The arcs correspond to the pairs of activities that are adjacent.
• A REL graph corresponding to a layout is planar because the arcs connecting two adjacent activities can always be drawn passing through their common border of positive length.
Relationship (REL) Diagram
• A Relationship (REL) Diagram is also an undirected graph, generated from the REL chart, but it is in general nonplanar.
• A REL diagram, including the U closeness values, has M(M-1)/2 arcs. Since a planar graph can have at most 3M-6 arcs, a REL diagram will be nonplanar if M(M-1)/2 > 3M-6.
M(M-1)/2 > 3M-6 M 5.
• A REL graph is a subgraph of the REL diagram.
• For M 5, at most 3M-6 out of M(M-1)/2 relationships can be satisfied through adjacency in a REL graph.
An upper bound on LSa, LSaUB, is the sum of the 3M-6 longest V(rij)’s.
Maximally Planar Graph (MPG)
• A planar graph with exactly 3M-6 arcs is called Maximally Planar Graph (MPG).
Not MPG sincehas only 5 arcs(5 < 6 = 3M-6)
MPG sincehas 6 arcs
• The interior faces of a graph are the bounded regions formed by its arcs, and its exterior face is the unbounded region formed by its outside arcs.
IF1 IF2
IF3
EF The tetrahedron has three interior faces (IF1, IF2 and IF3) and an exterior face (EF)
Graph-based Method
Graph-based Method
Graph-based Method
Graph-based Method
Graph-based Method
Graph-based Method
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FL1 : 73
Improvement Procedures
• Pairwise exchange method– Find a feasible solution– Consider all pairwise interchanges– Perform the interchange that yields greatest
total cost reduction– Continue until no more reduction
Pairwise Exchange
Pairwise Exchange
Pairwise Exchange
Pairwise Exchange
FL1 : 78
A(1), B(2), C(3), D(4) A(2), B(1), C(3), D(4)
A(2), B(1), C(3), D(4) A(3), B(1), C(2), D(4)
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