Layout

1
Layout
2
What Is Layout Planning?

• What centres should the layout include?
• How much space and capacity does each centre
  need?
• How should each centres space be configured?
• Where should each centre be located?

3
Strategic Issues

• Facilitating the flow of materials
• Increasing the efficient utilization of labour
  and equipment
• Increasing customer convenience
• Reducing hazards to workers
• Improving employee morale
• Improving communication

4
Criteria for a Good Layout

• Maximum flexibility
• Maximum co-ordination
• Maximum use of volume
• Maximum visibility
• Maximum accessibility

5
Criteria for a Good Layout

• Minimum distance
• Minimum handling
• Minimum discomfort
• Inherent safety
• Maximum security
• Efficient material flow
• Identification

6
Layout Types

• Process Layout
• Product Layout
• Fixed-Position Layout
• Hybrid Layout - Cells

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Layout Types - Process Layout
8
Layout Types - Process Layout

• Organizes resources around the process and groups
  work stations or departments according to
  function
• Intermittent, low volume, high-variety

9
Layout Types - Process Layout
Lathes
Grinding
Forging
Painting
Drills
Welding
Milling
Foundry
Office
machines
(a) Layout of a job shop
10
Layout Types - Process Layout
Lathes
Grinding
Forging
Painting
Drills
Welding
Milling
Foundry
Office
machines
(a) Layout of a job shop
11
Layout Types - Process Layout
Lathes
Grinding
Forging
Painting
Drills
Welding
Milling
Foundry
Office
machines
(a) Layout of a job shop
12
Layout Types - Process Layout
Lathes
Grinding
Forging
Painting
Drills
Welding
Milling
Foundry
Office
machines
(a) Layout of a job shop
13
Layout Types - Process Layout
Lathes
Grinding
Forging
Painting
Drills
Welding
Milling
Foundry
Office
machines
(a) Layout of a job shop
14
Layout Types - Process Layout

• Advantages
• General purpose, flexible resources are less
  capital intensive
• Less vulnerable to changes in product mix or new
  market strategies
• Equipment utilization can be higher, because not
  dedicated to one product line
• Employee supervision can be more specialized

15
Layout Types - Process Layout

• Disadvantages
• Slower processing rates
• Lost production time during setups
• More capital and more floor space tied up with
  inventory
• Longer manufacturing lead times
• Costly materials handling, requiring variable
  path devices
• Production planning and control more difficult

16
Layout Types - Process Layout

• A major challenge in designing process layouts is
  to identify dominant flow patterns among the
  jumbled traffic and to locate centres so that
  materials handling is minimized.

17
Layout Types - Product Layout
18
Layout Types - Product Layout

• Dedicates resources to a product or closely
  related product family
• Repetitive, high-volume, continuous production
• Workstations or departments are arranged in a
  linear path, which is consistent with the routing
  sequence of the product.

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Layout Types - Product Layout
Station 1
Station 2
Station 3
Station 4
(b) Layout of a production line
20
Layout Types - Product Layout
Station 1
Station 2
Station 3
Station 4
(b) Layout of a production line
21
Layout Types - Product Layout
Station 1
Station 2
Station 3
Station 4
(b) Layout of a production line
22
Layout Types - Product Layout
Station 1
Station 2
Station 3
Station 4
(b) Layout of a production line
23
Layout Types - Product Layout

• Advantages
• Faster processing rates
• Lower inventories
• Infrequent setups

24
Layout Types - Product Layout

• Disadvantages
• More risk of layout redesign
• Less flexible
• For low volume, dedicated resources have low
  utilization

25
Layout Types - Product Layout

• Challenge in designing product layouts
• Minimize resources used to achieve desired output
  rate
• Balance tasks, equalize the workload assigned to
  resources

26
Layout Types - Fixed-position Layout
27
Layout Types - Fixed-position Layout

• Product is fixed in place. Resources come to the
  product, minimizing number of times product must
  be moved.
• Used for
• Very large products, ships, roads, power plants,
  airplanes
• Service of fragile or bulky items

28
Layout Types - Fixed-position Layout
Process
Process
Process
Product
Process
Process
29
Layout Types - Fixed-position Layout

• Advantages
• Material movement is reduced to a minimum.
• The task is usually carried out by a gang of
  operators, hence continuity of operators and
  responsibility is required.
• Production centres often operate independently of
  each other, and effective scheduling can be
  planned to ensure minimum total production time.

30
Layout Types - Fixed-position Layout

• Limitations
• Movement of machines and equipment to the
  production centre may be costly and time
  consuming.
• Positioning of the material or object or machines
  may be cumbersome and costly.
• Machine and equipment utilisation is usually low,
  owing to handling and positioning time.
• High grades of skill are required.

31
Muthers P-Q Chart
32
Group Technology
33
Group Technology
One Worker, Multiple Machines
Machine 2
Machine 3
Machine 1
Materials in
Finished goods out
Machine 4
Machine 5
34
Group Technology
35
Group Technology
Parts Families
Source Mikell P. Groover. Automation, Production
Systems, and Computer-Aided Manufacturing.
Englewood Cliffs, NJ Prentice-Hall, 1980, p.
540. Used by permission.
36
Group Technology
37
Group Technology
Drilling
Milling
Lathing
D
D
L
L
M
M
D
D
M
M
L
L
Grinding
L
L
M
M
G
G
Assembly
L
L
G
G
A
A
Receiving and shipping
G
G
A
A
38
Group Technology
Drilling
Milling
Lathing
D
D
L
L
M
M
D
D
M
M
L
L
Grinding
L
L
M
M
G
G
Assembly
L
L
G
G
A
A
Receiving and shipping
G
G
A
A
(a) Jumbled flows in a job shop without GT cells
39
Group Technology
Drilling
Milling
Lathing
D
D
L
L
M
M
D
D
M
M
L
L
Grinding
L
L
M
M
G
G
Assembly
L
L
G
G
A
A
Receiving and shipping
G
G
A
A
(a) Jumbled flows in a job shop without GT cells
40
Group Technology
(a) Jumbled flows in a job shop without GT cells
41
Group Technology
(b) Line flows in a job shop with three GT cells
42
Group Technology
(b) Line flows in a job shop with three GT cells
43
Group Technology
(b) Line flows in a job shop with three GT cells
44
Group Technology
(b) Line flows in a job shop with three GT cells
45
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Longhorn Machine
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Longhorn Machine
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Longhorn Machine
Figure 10.6
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Longhorn Machine
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Longhorn Machine
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Longhorn Machine
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Longhorn Machine
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Longhorn Machine
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Longhorn Machine
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Longhorn Machine
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Longhorn Machine
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Longhorn Machine
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Longhorn Machine
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Longhorn Machine

• Departments 3 and 6 close together
• Departments 1 and 6 close together
• Departments 2 and 5 close together
• Departments 4 and 5 close together

Figure 10.6
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Longhorn Machine

• Departments 3 and 6 close together
• Departments 1 and 6 close together
• Departments 2 and 5 close together
• Departments 4 and 5 close together

Example 10.1
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Longhorn Machine

• Departments 3 and 6 close together
• Departments 1 and 6 close together
• Departments 2 and 5 close together
• Departments 4 and 5 close together

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Example 10.1
62
Longhorn Machine

• Departments 3 and 6 close together
• Departments 1 and 6 close together
• Departments 2 and 5 close together
• Departments 4 and 5 close together

6
1
Example 10.1
63
Longhorn Machine

• Departments 3 and 6 close together
• Departments 1 and 6 close together
• Departments 2 and 5 close together
• Departments 4 and 5 close together

5
6
1
2
Example 10.1
64
Longhorn Machine

• Departments 3 and 6 close together
• Departments 1 and 6 close together
• Departments 2 and 5 close together
• Departments 4 and 5 close together

5
6
1
2
Figure 10.7
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Longhorn Machine
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Longhorn Machine
Example 10.2
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Longhorn Machine
Example 10.2
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Longhorn Machine
Example 10.2
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Longhorn Machine
Example 10.2
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Longhorn Machine
Example 10.2
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Longhorn Machine
Example 10.2
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A-1 Distribution Systems
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A-1 Distribution Systems
Figure 10.8
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A-1 Distribution Systems
Example 10.3
Trips to and Area Needed Department from
Dock (blocks) 1. Toasters 280 1 2. Air
conditioners 160 2 3. Microwaves 360 1 4. Stereo
s 375 3 5. TVs 800 4 6. Radios 150 1 7. Bulk
storage 100 2
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A-1 Distribution Systems
Example 10.3
Trips to and Area Needed Department from
Dock (blocks) Ratio Rank 1. Toasters 280 1 280/1
280 2. Air conditioners 160 2 160/2
80 3. Microwaves 360 1 360/1
360 4. Stereos 375 3 375/3 125 5. TVs 800 4 80
0/4 200 6. Radios 150 1 150/1 150 7. Bulk
storage 100 2 100/2 50
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A-1 Distribution Systems
Example 10.3
Trips to and Area Needed Department from
Dock (blocks) Ratio Rank 1. Toasters 280 1 280/1
280 2 2. Air conditioners 160 2 160/2
80 6 3. Microwaves 360 1 360/1
360 1 4. Stereos 375 3 375/3 125 5 5. TVs 800 4
800/4 200 3 6. Radios 150 1 150/1
150 4 7. Bulk storage 100 2 100/2 50 7
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A-1 Distribution Systems
Example 10.3
Trips to and Area Needed Department from
Dock (blocks) Ratio Rank 1. Toasters 280 1 280/1
280 2 2. Air conditioners 160 2 160/2
80 6 3. Microwaves 360 1 360/1
360 1 4. Stereos 375 3 375/3 125 5 5. TVs 800 4
800/4 200 3 6. Radios 150 1 150/1
150 4 7. Bulk storage 100 2 100/2 50 7
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A-1 Distribution Systems
Example 10.3
Trips to and Area Needed Department from
Dock (blocks) Ratio Rank 1. Toasters 280 1 280/1
280 2 2. Air conditioners 160 2 160/2
80 6 3. Microwaves 360 1 360/1
360 1 4. Stereos 375 3 375/3 125 5 5. TVs 800 4
800/4 200 3 6. Radios 150 1 150/1
150 4 7. Bulk storage 100 2 100/2 50 7
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A-1 Distribution Systems
Example 10.3
Trips to and Area Needed Department from
Dock (blocks) Ratio Rank 1. Toasters 280 1 280/1
280 2 2. Air conditioners 160 2 160/2
80 6 3. Microwaves 360 1 360/1
360 1 4. Stereos 375 3 375/3 125 5 5. TVs 800 4
800/4 200 3 6. Radios 150 1 150/1
150 4 7. Bulk storage 100 2 100/2 50 7
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A-1 Distribution Systems
Example 10.3
Trips to and Area Needed Department from
Dock (blocks) Ratio Rank 1. Toasters 280 1 280/1
280 2 2. Air conditioners 160 2 160/2
80 6 3. Microwaves 360 1 360/1
360 1 4. Stereos 375 3 375/3 125 5 5. TVs 800 4
800/4 200 3 6. Radios 150 1 150/1
150 4 7. Bulk storage 100 2 100/2 50 7
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A-1 Distribution Systems
Figure 10.9
Trips to and Area Needed Department from
Dock (blocks) Ratio Rank 1. Toasters 280 1 280/1
280 2 2. Air conditioners 160 2 160/2
80 6 3. Microwaves 360 1 360/1
360 1 4. Stereos 375 3 375/3 125 5 5. TVs 800 4
800/4 200 3 6. Radios 150 1 150/1
150 4 7. Bulk storage 100 2 100/2 50 7
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Zone Systems
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Zone Systems
Figure 10.10
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Zone Systems
Zones
Zones
Click to add title
Shipping doors
Tractor trailer
Tractor trailer
Feeder lines
Feeder lines
Figure 10.10
85
Zone Systems
Zones
Zones
Control station
Click to add title
Shipping doors
Tractor trailer
Tractor trailer
Feeder lines
Feeder lines
Figure 10.10
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Zone Systems
Figure 10.10
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Addison Wesley Longman Distribution Center
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Line Balancing
Green Grass, Inc. Big Broadcaster
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Line Balancing
Big Broadcaster
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Line Balancing
Big Broadcaster
Example 10.4
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Line Balancing
Big Broadcaster
Example 10.4
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Line Balancing
Big Broadcaster
A
40
Example 10.4
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Line Balancing
Big Broadcaster
Example 10.4
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Line Balancing
Big Broadcaster
Example 10.4
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Line Balancing
Big Broadcaster
Example 10.4
96
Line Balancing
Big Broadcaster
Example 10.4
97
Line Balancing
Big Broadcaster
Example 10.4
98
Line Balancing
Big Broadcaster
Example 10.4
99
Line Balancing
Big Broadcaster
Example 10.4
100
Line Balancing
Big Broadcaster
Example 10.4
101
Line Balancing
Big Broadcaster
Figure 10.11
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Line Balancing
Big Broadcaster
Example 10.5
103
Line Balancing
Big Broadcaster
Desired output rate 2400/week Plant operates 40
hours/week
r 2400/40 60 units/hour
Example 10.5
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Line Balancing
Big Broadcaster
Desired output rate 2400/week Plant operates 40
hours/week
r 2400/40 60 units/hour c 1/60 1
minute/unit 60 seconds/unit
Example 10.5
105
Line Balancing
Big Broadcaster
c 60 seconds/unit
Example 10.5
106
Line Balancing
Big Broadcaster
c 60 seconds/unit
Desired output rate 2400/week Plant operates 40
hours/week
TM 244 seconds/60 seconds 4.067 or 5
stations
Example 10.5
107
Line Balancing
Big Broadcaster
c 60 seconds/unit
Desired output rate 2400/week Plant operates 40
hours/week
TM 244 seconds/60 seconds 4.067 or 5
stations Efficiency 244\5(60)100 81.3
Example 10.5
108
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
Example 10.6
109
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
Cumm Idle Station Candidate Choice Time Time
Example 10.6
110
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
Cumm Idle Station Candidate Choice Time Time
S1 A A 40 20
Example 10.6
111
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
Cumm Idle Station Candidate Choice Time Time
S1 A A 40 20
Example 10.6
112
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
Cumm Idle Station Candidate Choice Time Time
S1 A A 40 20
Example 10.6
113
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
Cumm Idle Station Candidate Choice Time Time
S1 A A 40 20 S2 B,C C 50 10
Example 10.6
114
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
Cumm Idle Station Candidate Choice Time Time
S1 A A 40 20 S2 B,C C 50 10
Example 10.6
115
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S2
Cumm Idle Station Candidate Choice Time Time
S1 A A 40 20 S2 B,C C 50 10
Example 10.6
116
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S2
Cumm Idle Station Candidate Choice Time Time
S1 A A 40 20 S2 B,C C 50 10 S3 B,F,G B 30 30
Example 10.6
117
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S2
Cumm Idle Station Candidate Choice Time Time
S1 A A 40 20 S2 B,C C 50 10 S3 B,F,G B 30 30
Example 10.6
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Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S2
Cumm Idle Station Candidate Choice Time Time
S1 A A 40 20 S2 B,C C 50 10 S3 B,F,G B 30 30
Example 10.6
119
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S2
Cumm Idle Station Candidate Choice Time Time
S1 A A 40 20 S2 B,C C 50 10 S3 B,F,G B 30 30
E,F,G F 55 5
Example 10.6
120
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S2
Cumm Idle Station Candidate Choice Time Time
S1 A A 40 20 S2 B,C C 50 10 S3 B,F,G B 30 30
E,F,G F 55 5
Example 10.6
121
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S3
S2
Cumm Idle Station Candidate Choice Time Time
S1 A A 40 20 S2 B,C C 50 10 S3 B,F,G B 30 30
E,F,G F 55 5
Example 10.6
122
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S3
S2
Example 10.6
123
Line Balancing
Big Broadcaster
c 60 seconds/unit TM 5 stations Efficiency
81.3
S1
S3
S4
S2
S5
Figure 10.12