hybrid layout

8/17/2019 Hybrid Layout

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Hybrid Layouts


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Hybrid Layouts

Hybrid layouts modify and/or combinesome aspects of product and process

layouts. Examples:

Group technology & manufacturing cells – used in Justin !ime manufacturing

Grocery stores

!hree hybrid layouts: "ellular layouts #presented by $aria %oig

'lexible manufacturing systems #presented by (rian(arnes


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Hybrid Layouts: "ellularlayouts

"ellular layouts group dissimilar

machines into )or* centers

#called cells that process families

of parts )ith similar shapes or

re+uirements.

"ombines the ,exibility of a process layout )iththe e-ciency of a product layout.


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Designing Hybrid Layouts One of the most popular hybrid layouts uses

Group Technology (GT) and a cellular layout GT has the advantage of bringing the eciencies

of a product layout to a process layoutenvironment


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Process Flows before the Use of

GT Cells


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Process Flows after the Use of GT

Cells


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"haracteristics of the process:

"ells are arranged in relation to each other so that materialmoement is minimied.

Large machines that cannot be split among cells arelocated near to the cells that use them (point of use)

!he layout of machines )ithin each cell resembles a small

assembly line. 0d1ustments can be used to arrange the machines )ithin

the cell.

"omputer programs can be used to locate cells.


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Example:

$achines are grouped by function into four distinctdepartments.

"omponent parts manufactured in the process layoutsection of the factory are later assembled into a 2nishedproduct on the assembly line.

!he parts follo) di3erent ,o) paths through the shop. !hree representatie routings4 for parts 04 (4 and ".

5or*ers are s*illed )ithin a single department and canoperate more than one machine at a time.


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6otice:

!he distance that each part must trael beforecompletion

the irregularity of the part routings

0mount of 7paper)or*8 needed to direct the ,o) ofeach indiidual part and to con2rm that the right

operation has been performed

Original

Process

Layouts


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In its current form, there is no

apparent pattern to the routings.

PRODUCT FLOW ANALYSIS(PFA) reorders part routing

matries to identi!" !ami#ies o!

parts $it% simi#ar proessing

re&uirements'

If we reorder the matrix listing

which parts have four machines

in common, three...Part Routing Matrix


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Part Routing Matrix Reordered to Highlight Cells

Revised Layout with Three Cells


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0dantages: %educed material handling

and transit time

%educed setup time %educed )or*inprocess

inentory

(etter use of humanresources

multifunctional )or*ers

Easier to control

Easier to automate

Disadvantages: Inadequate part families

Poorly balanced cells

Expanded training and

scheduling of worers

Increased capital investment


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Types of Layout - ExapleManufacturing Cell

!niated Picture


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!n exaple of a hy"rid layout


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Types of Layout - Exaple!utoated Manufacturing Cell



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Types of Layout - Exaple#lexi"le Manufacturing Cell



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Types of Layout - Exaple!utoated Manufacturing Cell



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Types of Layout - Exaple#lexi"le Manufacturing Cell


ypes o ayou


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$or% Cell !sse"ly or Production line-oriented arrangeent ofachines and personnel in what is ordinarily a process-oriented facility& Cells can "e fored on a teporary

"asis&Exaple' (o" shop with rearranged achinery and

personnel to produce )* uni+ue control panels

#ocused $or%

Center

! peranent asse"ly-line-oriented arrangeent ofachines and personnel in what is ordinarily a process-oriented facility

Exaple' anufacturing of pipe "rac%ets at a

shipyard

#ocused #actory ! peranent facility to produce a product or coponent

in a product-oriented facility

Exaple' a plant to produce window echaniss for

autoo"iles

ypes o ayouWork Cell Focused Work Center and

Focused Factory


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9traightline 'lo) attern )hen possible

(ac*trac*ing *ept to a $inimum

redictable roduction !ime

Little ;nprocess materials storage


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!ew Trends in "anufacturing

Layouts

=esigned for +uality and ,exibility

0bility to +uic*ly shift to di3erent productmodels or to di3erent production rates

"ellular layout )ithin larger process layouts 0utomated material handling

>shaped production lines use to betteraccomplish ow control

$ore open )or* areas )ith fe)er )alls4partitions4 or other obstacles

9maller and more compact factory layouts

Less space proided for storage of inentoriesthroughout the layout


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Wrap#up$ttaining Lean Production

'ocus on inentory reduction

(uild systems that help employees

%educe space re+uirements

=eelop close relationships )ith suppliers Educate suppliers Eliminate all but alueadded actiities

=eelop the )or*force

$a*e 1obs more challenging

9et sights on perfection?

hybrid layout

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