m3 layout planning

7/29/2019 M3 Layout Planning

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JTM3023: INDUSTRIAL

ENGINEERING

FACILITIES LAYOUT


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JTM3023-M3 Mohd Norhasni 2

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



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



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



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


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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40 un its required


Min imum




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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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


40 un its required


Min imum


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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m3 layout planning

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