Facilities Chapter 5

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FacilitiesChapter 5
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Objectives

• Facility Layouts
• Process Layout Design
• Product Layout Design
• Hybrid Layouts
• Facility Location

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Facility Layouts

• Layout characteristics
• Min handling cost, max utilization
• Safety, security, quality, flexibility
• Basic layouts
• Process layout
• Product layout
• Fixed position layout

4
Compare
PRODUCT LAYOUT PROCESS LAYOUT
1. Description Sequential arrangement Functional
grouping of machines of machines 2. Type of
Process Continuous, mass Intermittent, job
shop production, mainly batch
production, assembly mainly fabrication 3. Produ
ct Standardized Varied, 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
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 Somewhat
static Complex dynamic 13. Layout decision Line
balancing Machine location 14. Goal Equalize work
at Minimize material each station handling
cost 15. Advantage Efficiency Flexibility
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Designing Process Layouts

• Block Diagramming
• Minimize nonadjacent loads
• Use when quantitative data is available
• Relationship Diagramming
• Based on location preference between areas
• Use when quantitative data is not available

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Block Diagramming

• Create load summary chart
• Calculate composite (2 way) movements
• Develop trial layouts minimizing number of
  nonadjacent loads

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Load Summary Chart
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Relationship Diagramming

• Used when quantitative data is not available
• Muthers grid table displays managers preferences
  for relative (pair wise) department locations
• Denote location preferences with weighted lines
  in a diagram

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Muthers Grid Table
A Absolutely necessary E Especially
important I Important O Okay U Unimportant X U
ndesirable
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Computerized Layout Solutions

• CRAFT block diagramming
• CORELAP relationship diagramming
• Simulation

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Service Layouts

• Tailored to customer needs
• Max flow and exposure
• Computer programs consider
• Shelf space
• Demand
• Profitability
• Aesthetically pleasing

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Designing Product Layouts

• Arranged in assembly line
• Precedence diagram of tasks
• Jobs divided into work elements
• Work elements assigned to workstations
• Workload balanced along the line

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Line Balancing

• Balance the amount of work at each workstation
• Achieve a constant throughput with high
  efficiency
• Line balancing process
• Precedence diagram
• Desired cycle time
• Min number of workstations
• Group elements into workstations with acceptable
  efficiency

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Precedence Table
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Hybrid Layouts

• Cellular layouts
• Group machines into machining cells
• Flexible manufacturing systems
• Automated machining material handling systems
• Mixed-model assembly lines
• Produce variety of models on one line

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Cellular Layouts

• Identify flow of similar parts
• Group machines into cells
• Arrange cells to min material movement
• Locate shared machines where cells connect

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Manufacturing Cell
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FMS Layout

• Automated machining, material handling, tool
  changers
• Computer controlled system
• Designed around part sizes and flow times

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Mixed Model Assembly Lines

• Produce multiple models in any order on one
  assembly line
• Issues in mixed model lines
• Line balancing
• U-shaped line
• Flexible workforce
• Model sequencing

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Facility Location

• Types of facilities
• Heavy manufacturing
• Light industry
• Warehouses and distribution centers
• Retail and service
• Location factors
• Standard factors
• Global, regional, site factors
• Location incentives

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Location Analysis

• Location factor rating
• Center-of-gravity technique
• Long-distance technique