ch09 layout strategy

8/19/2019 Ch09 Layout Strategy

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OperationsOperations

ManagementManagement

Layout StrategyLayout StrategyChapter 9Chapter 9


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OutlineOutline

♦GLOBAL COMPANY PROFIL! MC"ONAL"#S

♦$% S$RA$GIC IMPOR$ANC OF LAYO&$"CISIONS

♦$YPS OF LAYO&$♦FI'"(POSI$ION LAYO&$

♦PROCSS(ORIN$" LAYO&$

♦ Computer So)t*are )or Pro+ess(Oriente, Layouts♦ -or. Cells

♦ $he Fo+use, -or. Center an, the Fo+use, Fa+tory


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Outline ( Continue,Outline ( Continue,

♦OFFIC LAYO&$

♦R$AIL LAYO&$♦ Ser/i+es+apes

♦-AR%O&SING AN" S$ORAG LAYO&$S♦ Cross("o+.ing

♦ Ran,om Sto+.ing

♦ Customi0ing

♦RP$I$I1 AN" PRO"&C$(ORIN$" LAYO&$♦ Assem2ly(Line Balan+ing


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Learning O23e+ti/esLearning O23e+ti/es

-hen you +omplete this +hapter4 you shoul, 2ea2le to !

Identify or Define: ♦ Fi5e,(position layout♦ Pro+ess(oriente, layout♦ -or. +ells♦ Fo+use, *or. +enter♦ O))i+e layout♦ Retail layout♦ -arehouse layout♦ Pro,u+t(oriente, layout♦ Assem2ly(line )a+tory


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Learning O23e+ti/esLearning O23e+ti/es

-hen you +omplete this +hapter4 you shoul, 2ea2le to !

Describe or explain:

♦ %o* to a+hie/e a goo, layout )or the pro+ess)a+ility

♦ %o* to 2alan+e pro,u+tion )lo* in a repetiti/e or

pro,u+t(oriente, )a+ility


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M+"onal,#s ( Ne* 6it+hen LayoutM+"onal,#s ( Ne* 6it+hen Layout

♦0ift1 ma2or inno*ation - 3itc1en design♦ +o food prepared a1ead e4cept patty

♦ limination of some steps, s1ortening of ot1ers

♦ +e6 %n toasting mac1ine 8 seconds *s .# seconds

♦ Repositioning condiment containers 8one motion, not t6o

♦ )and6ic1es assem%led in order

♦ Prodction le*els controlled %y compter

♦ :iscard only meat 61en sand6ic1es do not sell fast enog1♦ )a*ings of ;##,###,### per year in food costs


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M+"onal,#s ( Ne* 6it+hen LayoutM+"onal,#s ( Ne* 6it+hen Layout

♦+o food prepared a1ead e4cept patty♦limination of some steps, s1ortening of ot1ers

♦+e6 %n toasting mac1ine 8 seconds *s .#

seconds

♦Repositioning condiment containers 8one

motion, not t6o


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Inno/ation at M+"onal,#sInno/ation at M+"onal,#s

♦ &ndoor seating 895#


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O23e+ti/es o) the Layout StrategyO23e+ti/es o) the Layout Strategy

♦:e*elop an economical layot 61ic1 6ill meet t1e

re>irements of?♦ prodct design and *olme 8prodct strategy

♦ process e>ipment and capacity 8process strategy

♦ >ality of 6or3 life 81man resorce strategy

♦ %ilding and site constraints 8location strategy


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$ypes o) Layouts$ypes o) Layouts

♦0i4ed-position layot♦Process-oriented layot

♦Office layot

♦Retail layot♦@are1ose layot

♦Prodct-oriented layot


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-hat is Fa+ility Layout-hat is Fa+ility Layout

♦ Aocation or arrangement of e*eryt1ing 6it1in B

arond %ildings

♦ O%2ecti*es are to ma4imize♦ Cstomer satisfaction

♦ (tilization of space, e>ipment, B people

♦ fficient flo6 of information, material, B people♦ mployee morale B safety


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Strategi+ Importan+e o) LayoutStrategi+ Importan+e o) Layout

Proper layout ena2les!♦Hig1er tilization of space, e>ipment,and people

♦ &mpro*ed flo6 of information, materials, or people

♦ &mpro*ed employee morale and safer 6or3ingconditions

♦ &mpro*ed cstomer/client interaction

♦0le4i%ility


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Si5 Layout StrategiesSi5 Layout Strategies

♦ 0i4ed-position layot♦ large %l3y pro2ects sc1 as s1ips and %ildings

♦ Process-oriented layot♦ deals 6it1 lo6-*olme, 1ig1-*ariety prodction 8D2o%

s1opE, intermittent prodction

♦ Office layot♦ positions 6or3ers, t1eir e>ipment, and spaces/offices

to pro*ide for mo*ement of information


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Si5 Layout Strategies ( +ontinue,Si5 Layout Strategies ( +ontinue,

♦ Retail/ser*ice layot♦ allocates s1elf space and responds to cstomer

%e1a*ior

♦ @are1ose layot♦ addresses trade-offs %et6een space and material

1andling

♦ Prodct-oriented layot♦ see3s t1e %est personnel and mac1ine se in

repetiti*e or continos prodction


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Layout StrategiesLayout Strategies

Project(fixed-position)

Job Shop(Process-oriented)

Office Retail Warehouse(storage)

Repetitive

/ontinuous(product-oriented)

!xa"ples

Pittsburgh

Airport

Problem

&ngal )1ipFilding Corp'

Trmp Plaza

)1oldiceHospital

Oli*e

Garden

=llstate&nsrance

Microsoft

roger


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Layout 5ample ( O))i+eLayout 5ample ( O))i+e


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Re7uirements o) a Goo, LayoutRe7uirements o) a Goo, Layout

an nderstanding of capacity and spacere>irements

selection of appropriate material 1andling

e>ipmentdecisions regarding en*ironment and

aest1etics

identification and nderstanding of t1ere>irements for information flo6

identification of t1e cost of mo*ing %et6een t1e*arios 6or3 areas


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Constraints on Layout O23e+ti/esConstraints on Layout O23e+ti/es

♦ Prodct design B *olme

♦ Process e>ipment B capacity

♦ Jality of 6or3 life♦ Filding and site

i l ,L S i l ,


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Layout Strategies4 5amples4 an,Layout Strategies4 5amples4 an,Criteria Criteria

)er*ice/retail :rg store

Grocery store

:epartment store

4pose cstomer to 1ig1

margin items

)torage :istri%tor

@are1ose

Minimize storage and

1andling costs

Prodct oriented TI assem%ly line Minimize line im%alance,

delay, and idle time

Layout strategy 5ample Criteria

) C i


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Areas o) Con+ern in LayoutAreas o) Con+ern in LayoutStrategyStrategy

Aayot

)trategy

Material0lo6

Commnication

@or3

Cell

)afety

Material

=ttri%tes

@are1osing

)er*ice

=reas


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Fi5e,(Position LayoutFi5e,(Position Layout

♦ :esign is for stationary pro2ect

♦@or3ers and e>ipment come to site

♦ Complicating factors♦ Aimited space at site

♦ C1anging material needs

F C li i Fi ,F t C li ti Fi ,


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Fa+tors Compli+ating a Fi5e,Fa+tors Compli+ating a Fi5e,Position LayoutPosition Layout

♦ T1ere is limited space at *irtally all sites

♦ =t different stages in t1e constrction process,

different materials are needed – t1erefore,

different items %ecome critical as t1e pro2ect

de*elops

♦ T1e *olme of materials needed is dynamic


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Pro+ess(Oriente, LayoutPro+ess(Oriente, Layout

♦ :esign places departments 6it1 large flo6s of

material or people toget1er

♦ :epartment areas 1a*ing similar processeslocated in close pro4imity♦ e'g', =ll 4-ray mac1ines in same area

♦ (sed 6it1 process-focsed processes


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mergen+y Room Layoutmergen+y Room Layout

) 7 r g e r y

R a d i o l o g y 'R' %eds P1armacy Filling/e4it

'R'Triage

room5'R' =dmissions

Patient B ( errati+

pa+ema.er

Patient A (

2ro.en leg

Hall6ay

St i " l iSteps in "e eloping a


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Steps in "e/eloping a Steps in "e/eloping a Pro+ess(Oriente, LayoutPro+ess(Oriente, Layout

Constrct a Dfrom-to matri4E

" :etermine space re>irements for eac1 department

. :e*elop an initial sc1ematic diagram

$ :etermine t1e cost of t1is layot

5 Fy trial-and-error 8or more sop1isticated means, tryto impro*e t1e initial layot

Prepare a detailed plan t1at e*alates factors inaddition to transportation cost


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Cost o) Pro+ess(Oriente, LayoutCost o) Pro+ess(Oriente, Layout

jdepartmentandidepartment

betweenloadamovecost toC

jdepartmenttoidepartment

frommovedloadsof numberX

sdepartmentindividual ji,sdepartmentor

centersworkof numbertotalnwhere

CXcostMinimize

ij

ij

n

1i

n

1 jijij

=

=

=

=

= ∑∑= =


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Inter,epartmental Flo* o) PartsInter,epartmental Flo* o) Parts

8 : ; < =

8

:

;

<

=

8>> > > >

:> 8> >

> > 8>>

>

>

Inter,epartmental Flo* GraphInter,epartmental Flo* Graph


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Sho*ing Num2er o) -ee.ly Loa,sSho*ing Num2er o) -ee.ly Loa,s

8>>

:>

8>

9 >

9 >

8>>

" .

$ 5


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Possi2le Layout 8Possi2le Layout 8

=ssem%ly:epartment

8

Printing:epartment

8"

Mac1ine )1op:epartment

8.

Recei*ing:epartment

8$

)1ipping:epartment

85

Testing:epartment

8

Room Room " Room "

Room $ Room 5 Room #<

$#<



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Sho*ing Num2er o) -ee.ly Loa,sSho*ing Num2er o) -ee.ly Loa,s

8>>

:>

8 >

9 >

9 >8>>

" .

$ 5


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Possi2le Layout :Possi2le Layout :

Painting:epartment

8"

=ssem%ly:epartment

8

Mac1ine )1op:epartment

8.

Recei*ing:epartment

8$

)1ipping:epartment

85

Testing:epartment

8

Room Room " Room "

Room $ Room 5 Room #<

$#<

Computer Programs to Assist inComputer Programs to Assist in


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Computer Programs to Assist inComputer Programs to Assist inLayoutLayout

♦CR=0T

♦)P=CCR=0T

♦CR=0T .-:

♦M(AT&PA

♦CORA=P

♦

=A:P♦CO0=:

♦0=:) - e4pert system

Out Patient %ospital 5ampleOut(Patient %ospital 5ample


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Out(Patient %ospital 5ampleOut(Patient %ospital 5ampleCRAF$CRAF$

= = = = F F

= = = = F F

: : : : : :C C : : : :

0 0 0 0 0 :

:

: : : : F F

: : : : F F

: : : C C : 0

= = = = = 0

= = = 0 0 0

" . $ 5 " . $ 5

"

.

$

5

"

.

$

5

Total cost? "#,##st' Cost Redction '##&teration #

Total cost? $,.9#st' Cost Redction 7#'&teration .

Legen,!

= K 4ray/MR& rooms

F K la%oratories

C K admissions

: K e4am rooms

K operating rooms

0 K reco*ery rooms


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Cellular Layout ( -or. CellsCellular Layout ( -or. Cells

♦ )pecial case of prodct-oriented layot - in 61at

is ordinarily a process-oriented facility

♦ Consists of different mac1ines %rog1t toget1er toma3e a prodct

♦ Temporary arrangement only

♦ 4ample? =ssem%ly line set p to prodce .###identical parts in a 2o% s1op

Impro/ing Layouts 2y Mo/ing toImpro/ing Layouts 2y Mo/ing to


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Impro/ing Layouts 2y Mo/ing toImpro/ing Layouts 2y Mo/ing tothe -or. Cell Con+eptthe -or. Cell Con+ept

. ll ,- . C ll S A,


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-or. Cells ( Some A,/antages-or. Cells ( Some A,/antages

♦ Redced 6or3-in-process in*entory♦ Aess floor space re>ired

♦ Redced ra6 material and finis1ed goods

in*entories re>ired♦ Redced direct la%or costs

♦ Heig1tened sense of employee participation

♦ &ncreased tilization of e>ipment mac1inery

♦ Redced in*estment in mac1inery and e>ipment

- . C ll A,- . C ll A, t


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-or. Cell A,/antages-or. Cell A,/antages

&n*entory0loor space

:irect la%or costs

>ipment tilizationmployee

participation

Jality

- . C ll Fl Pl- . C ll Fl Pl


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-or. Cell Floor Plan-or. Cell Floor Plan

O))i+eO))i+e

$ool Room$ool Room -or. Cell-or. Cell

Sa*sSa*s "rills"rills

Re7uirements )or CellularRe7uirements )or Cellular


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Re7uirements )or CellularRe7uirements )or CellularPro,u+tionPro,u+tion

♦ &dentification of families of prodcts - grop

tec1nology codes

♦Hig1 le*el of training and fle4i%ility on t1e part oft1e employees

♦it1er staff spport or fle4i%le, imaginati*e

employees to esta%lis1 t1e 6or3 cells initially♦Test 8po3a-yo3e at eac1 station in t1e cell

-or. Cells4 Fo+use, -or.-or. Cells4 Fo+use, -or.


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-or. Cells4 Fo+use, -or.-or. Cells4 Fo+use, -or.Centers an, the Fo+use, Fa+toryCenters an, the Fo+use, Fa+tory

-or. Cell = temporary assem%ly-line-oriented arrangement ofmac1ines and personnel in 61at is ordinarily a process-oriented facility4ample? 2o% s1op 6it1 rearranged mac1inery andpersonnel to prodce .# ni>e control panels

Fo+use, -or.Center

= permanent assem%ly-line-oriented arrangement ofmac1ines and personnel in 61at is ordinarily a process-oriented facility4ample? manfactring of pipe %rac3ets at a s1ipyard

Fo+use, Fa+tory = permanent facility to prodce a prodct or componentin a prodct-oriented facility

4ample? a plant to prodce 6indo6 mec1anisms for

atomo%iles


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O))i+e LayoutO))i+e Layout


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O))i+e LayoutO))i+e Layout

♦ :esign positions people, e>ipment, B officesfor ma4imm information flo6

♦ =rranged %y process or prodct♦ 4ample? Payroll dept' is %y process

♦ Relations1ip c1art sed

♦ 4amples♦ &nsrance company

♦ )oft6are company

© 1995

Corel Corp.

O))i+e Layout Floor PlanO))i+e Layout Floor Plan


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O))i+e Layout Floor PlanO))i+e Layout Floor Plan

A++ountingA++ounting

ManagerManager Bran, 'Bran, '

Finan+eFinan+eFin A++t

Relationship ChartRelationship Chart


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Relationship ChartRelationship Chart

PresidentO

" Costing (= =. ngineering &

O

$ President


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O))i+e Relationship ShartO))i+e Relationship Shart

President

" C1ief Tec1nology Officer

. ngineeripment ca%inet

P1otocopy e>ipment

9 )torage room

9 )torage room

&

I

I

A

&

O

IO

I

O

A

OA

'

O&

A

I I

&A

I

I

A

'

&

&

O

O

&O

Ial' Closeness

= =%soltelynecessary

speciallyimportant

& &mportant

O Ordinary O

( (nimportant

L +ot desira%le

RetailDSer/i+e LayoutRetailDSer/i+e Layout


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RetailDSer/i+e LayoutRetailDSer/i+e Layout

♦ :esign ma4imizes prodct e4posre to cstomers

♦ :ecision *aria%les

♦ )tore flo6 pattern♦ =llocation of 8s1elf space to prodcts

♦ Types♦

Grid design♦ 0ree-flo6 design

Video

Retail Layouts (Retail Layouts (


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Retail Layouts ySome Rules o) $hum2Some Rules o) $hum2

♦ Aocate 1ig1-dra6 items arond t1e perip1ery of t1e store

♦ (se prominent locations sc1 as t1e first or last aisle for1ig1-implse and 1ig1 margin items

♦ Remo*e crosso*er aisles t1at allo6 cstomers t1eopportnity to mo*e %et6een aisles

♦ :istri%te 61at are 3no6n in t1e trade as Dpo6er itemsE8items t1at may dominate a s1opping trip to %ot1 sides ofan aisle, and disperse t1em to increase t1e *ie6ing of ot1eritems

♦ (se end aisle locations %ecase t1ey 1a*e a *ery 1ig1e4posre rate

Retail DSer/i+e Layout (Retail DSer/i+e Layout (


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yy

Gri, "esignGri, "esign

O))i+eO))i+e CartsCartsChe+.(Che+.(

outout

Gro+ery StoreGro+ery StoreMeatBrea,

M

i l .

Prod7c

e

0rozen

0o

ods

Store Layout ( *ith "airy4 Brea,4Store Layout ( *ith "airy4 Brea,4


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y y%igh "ra*er Items in Corners%igh "ra*er Items in Corners

RetailDSer/i+e Layout (RetailDSer/i+e Layout (l i


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Free(Flo* "esignFree(Flo* "esign

FeatureFeature

"isplay"isplay$a2le$a2le

$rans$ransCounterCounter

Apparel StoreApparel Store

Retail Store Shel) Spa+eRetail Store Shel) Spa+elPl


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PlanogramPlanogram

♦ Compterized tool for

s1elf-space

management

♦ Generated from store


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yy

?Ser/i+es+ape@ Consi,ers?Ser/i+es+ape@ Consi,ers

♦ Ambient conditions - %ac3grond c1aracteristics

sc1 as lig1ting, sond, smell, and temperatre'

♦Spatial layout and functionality - 61ic1 in*ol*ecstomer circlation pat1 planning

♦Signs, Symbols, and Artifacts - c1aracteristics of

%ilding design t1at carry social significance

-arehouse Layout-arehouse Layout


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-arehouse Layout-arehouse Layout

♦ :esign %alances space 8c%e tilization B

1andling cost

♦ )imilar to process layot

♦ &tems mo*ed %et6een doc3B *arios storage areas

♦ Optimm layot depends on♦ Iariety of items

stored

♦ +m%er of items pic3ed

-arehouse Layout Floor Plan-arehouse Layout Floor Plan


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-arehouse Layout Floor Plan-arehouse Layout Floor Plan

ZonesZones

Conveyor Conveyor

TrucTruc

Order Picer Order Picer

Cross "o+.ingCross "o+.ing


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Cross "o+.ingCross "o+.ing

♦ Transferring goods♦ from incoming trc3s at

recei*ing doc3s♦ to outgoing trc3s at s1ipping

doc3s

♦ =*oids placing goods intostorage

♦ Re>ires sppliers pro*ideeffecti*e addressing 8%ar

codes and pac3aging t1atpro*ides for rapidtrans1ipment

!n-!n-

co"ingco"ingOutgoingOutgoing

© 1984-1994 T/Maker Co.

© 1995 Corel Corp.

Ran,om Sto+.ing Systems O)ten!Ran,om Sto+.ing Systems O)ten!


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Ran,om Sto+.ing Systems O)ten!Ran,om Sto+.ing Systems O)ten!

♦

Maintain a list of DopenE locations♦Maintain accrate records of e4isting in*entory

and its locations

♦)e>ence items on orders to minimize tra*el timere>ired to pic3 orders

♦Com%ine orders to redce pic3ing time

♦=ssign certain items or classes of items, sc1 as

1ig1 sage items, to particlar 6are1ose areasso t1at distance tra*eled is minimized

Pro,u+t(Oriente, LayoutPro,u+t(Oriente, Layout


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Pro,u+t Oriente, Layouto,u+t O e te, ayout

♦ 0acility organized arond prodct

♦ :esign minimizes line im%alance

♦ :elay %et6een 6or3 stations

♦ Types? 0a%rication line assem%ly line

Pro,u+t(Oriente, Re7uirementsPro,u+t(Oriente, Re7uirements


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Pro,u+t Oriente, Re7uirements7

♦ )tandardized prodct

♦ Hig1 prodction *olme

♦ )ta%le prodction >antities

♦ (niform >ality of ra6 materials B components

Pro,u+t(Oriente, Layout ( AssumptionsPro,u+t(Oriente, Layout ( Assumptions


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Pro,u+t Oriente, Layout AssumptionsPro,u+t Oriente, Layout Assumptions

♦Iolme is ade>ate for 1ig1 e>ipment tilization♦Prodct demand is sta%le enog1 to 2stify 1ig1

in*estment in specialized e>ipment

♦Prodct is standardized or approac1ing a p1ase ofits life cycle t1at 2stifies in*estment in specializede>ipment

♦)pplies of ra6 materials and components are

ade>ate and of niform >ality to ensre t1ey 6ill 6or3 6it1 specialized e>ipment

Pro,u+t(Oriente, Layout $ypesPro,u+t(Oriente, Layout $ypes


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y ypy yp

♦ =ssem%les fa%ricated parts

♦ (ses 6or3station

♦ Repetiti*e process

♦ Paced %y tas3s

♦ Falanced %y mo*ing tas3s

♦ Filds components

♦ (ses series of mac1ines

♦ Repetiti*e process

♦ Mac1ine paced

♦ Falanced %y p1ysical redesign

0a%rication Aine =ssem%ly Aine

Pro,u+t(Oriente, Layout A,/antagesPro,u+t(Oriente, Layout A,/antages


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Pro,u+t Oriente, Layout A,/antagesPro,u+t Oriente, Layout A,/antages

♦ Ao6er *aria%le cost per nit

♦ Ao6er material 1andling costs

♦ Ao6er 6or3-in-process

in*entories

♦ asier training B sper*ision

♦ Rapid t1rog1pt

Pro,u+t(Oriente, LayoutPro,u+t(Oriente, Layout"isa,/antages"isa,/antages


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"isa,/antages"isa,/antages

♦ Hig1er capital in*estment♦ )pecial e>ipment

♦ =ny 6or3 stoppage stops 61ole process

♦ Aac3 of fle4i%ility♦

Iolme♦ Prodct

An Assem2ly Line LayoutAn Assem2ly Line Layout


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y yy y

Repetiti/e LayoutRepetiti/e Layout


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p y

8 :

;

<

-or.-or.

O))i+eO))i+e

Belt Con/eyorBelt Con/eyor

-or.-or.

StationStation

Note! < tas.s or operationsE : *or. stationsNote! < tas.s or operationsE : *or. stations

-or. Station-or. Station

StationStation

Assem2ly Line Balan+ingAssem2ly Line Balan+ing


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♦ =nalysis of prodction lines

♦ +early e>ally di*ides 6or3 %et6een 6or3stations

61ile meeting re>ired otpt♦ O%2ecti*es

♦ Ma4imize efficiency

♦ Minimize nm%er of 6or3 stations

Assem2ly Line Balan+ingAssem2ly Line Balan+ing$he General Pro+e,ure$he General Pro+e,ure


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$he General Pro+e,ure$he General Pro+e,ure

♦ :etermine cycle time %y ta3ing t1e demand 8or prodction

rate per day and di*iding it into t1e prodcti*e time

a*aila%le per day

♦ Calclate t1e t1eoretical minimm nm%er of 6or3stations %y di*iding total tas3 time %y cycle time

♦ Perform t1e line %alance and assign specific assem%ly

tas3s to eac1 6or3 station

Assem2ly Line Balan+ing StepsAssem2ly Line Balan+ing Steps


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' :etermine tas3s 8operations"' :etermine se>ence

.' :ra6 precedence diagram

$' stimate tas3 times

5' Calclate cycle time

' Calclate nm%er of 6or3 stations

7' =ssign tas3s

' Calclate efficiency

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ch09 layout strategy

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