Process Layout

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Process Layout
Chapter 7
2
Redesigning a Process Through Layout Revision
Identify opportunity 1
Figure 7.1
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• Strategic Issues
• Facilitating the flow of materials
• Increasing the efficient utilization of labor and
  equipment
• Reducing hazards to workers
• Improving employee morale
• Improving communication

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Layout Types
(a) Layout of a job shop
Figure 7.3
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Flexible-Flow layout (funktionell verkstad)

• Fördelar med en funktionell verkstad
• flexibel, anpassningsbar till varierande
  produktionsförhållande, lätt att styra om
  produktionen till att tillverka nya produkter
• låg störningskänslighet, om en maskin går sönder
  kan man arbeta i en annan
• genom specialisering erhålls personal med
  specialistkunnande
• högt maskinutnyttjande kan åstadkommas

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• Nackdelar med en funktionell verkstad
• hög kapitalbindning, mycket produkter i arbete
  och stora mellanlager
• långa osäkra genomloppstider
• svåra planerings, lednings och
  administrationsproblem
• ofta långa transportvägar
• genom specialisering, kan den enskilde
  operatören bli låst till sin maskin

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Layout Types
(b) Layout of a production line
Figure 7.3
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Line-Flow layout (linjetillverkning)

• Fördelar med linjetillverkning
• kort genomloppstid
• mindre kapitalbindning
• mindre transporter
• arbetet lättare att planera och administrera än
  i en funktionell verkstad (när installationen är
  klar)

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Nackdelar med linjetillverkningIcke flexibel,
produktionsupplägg och maskiner anpassas till att
tillverka en speciell produkt vid en viss given
efterfråganStörningskänslighet, ett
maskinhaveri stoppar all produktion av
produktenKan i vissa fall leda till ensidiga
arbetsuppgifter
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Group Technology
One Worker, Multiple Machines
Figure 7.4
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Group Technology
(a) Jumbled flows in a job shop without GT cells
Figure 7.5
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Group Technology
(b) Line flows in a job shop with three GT cells
Figure 7.5
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• Designing Process Layouts
• Step 1 Gather Information
• Space Requirements by Center
• Available Space
• Closeness Factors
• Other Considerations
• Step 2 Develop a Block Plan
• Step 3 Design a Detailed Layout
• Aids for Process Layout Decisions

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Office of Budget Management
Figure 7.6
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Office of Budget Management
3 6 5 6 10 8 1 1 3 9 2 1

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Office of Budget Management

• Departments 1 and 6 close together
• Departments 3 and 5 close together
• Departments 2 and 3 close together

Figure 7.7
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Office of Budget Management

• Departments 1 and 6 close together
• Departments 3 and 5 close together
• Departments 2 and 3 close together

Figure 7.7
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Office of Budget Management

• Departments 1 and 6 close together
• Departments 3 and 5 close together
• Departments 2 and 3 close together

Figure 7.7
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Office of Budget Management

• Departments 1 and 6 close together
• Departments 3 and 5 close together
• Departments 2 and 3 close together

Figure 7.7
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Distance Measures
Euclidian Distance
Rectilinear Distance
dAB xA xB yA yB
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Office of Budget Management
Example 7.2
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Office of Budget Management
Figure 7.8
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Office of Budget Management
Figure 7.9
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Out-and-Back Warehouse
Figure 7.10
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Zone Systems
Figure 7.11
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• Designing Product Layouts
• Line Balancing
• Precedence Diagram
• Desired Output rate
• Cycle Time
• Theoretical Minimum
• Idle Time, Efficiency, and Balance Delay
• Finding a Solution

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Line Balancing
Green Grass, Inc. Big Broadcaster
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Line Balancing
Big Broadcaster
Example 7.3
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Line Balancing
Big Broadcaster
Example 7.3
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Line Balancing
Big Broadcaster
Example 7.3
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Line Balancing
Big Broadcaster
Example 7.4
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Line Balancing
Big Broadcaster
Example 7.4
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Line Balancing
Big Broadcaster
Example 7.4
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Line Balancing
Big Broadcaster
c 60 seconds/unit
Example 7.4
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Line Balancing
Big Broadcaster
c 60 seconds/unit
Example 7.4
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Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
Example 7.5
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Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
Example 7.5
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Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
Example 7.5
39
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S2
Example 7.5
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Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S2
Example 7.5
41
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S2
Example 7.5
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Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S2
Example 7.5
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Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S3
S2
Example 7.5
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Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S3
S4
S2
S5
Figure 7.13
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