Facility Layout

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Facility Layout

• Chapter 10
• pages 345-349, 359-360, 367-368

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MGMT 326
Quality Assurance
Products Processes
Planning Control
Foundations of Operations
Facilities
Managing Projects
Managing Quality
Facility Location
Managing Inventory
Introduction
Strategy
Product Design
Statistical Process Control
Linear Program- ming
Process Design
Facility Layout
Just-in-Time Lean Systems
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Presentation Outline

• Importance of layout planning
• Process and product layouts
• Office layouts
• Designing cellular layouts

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What Is Layout Planning?

• Layout planning is determining the best physical
  arrangement of resources within a facility
• Most facilities use either a product or a process
  layout

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Why is layout planning important?

• Eliminates unnecessary costs for space and
  materials handling
• Reduces work-in-process inventory
• Products goods and services faster
• Reduces distances that workers must travel in the
  workplace
• Improves communication and morale
• Increases retail sales
• Improves brand image

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Types of Layouts

• Process layouts Group similar resources together
• Product layoutsDesigned to produce a specific
  product, or a small number of products
  efficiently
• Hybrid layoutsCombine aspects of both process
  and product layouts
• Example cellular manufacturing
• Fixed-Position layouts Product is too large to
  move
• Examples building construction, shipyard
• Resources must be brought to where they are
  needed

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Process and Product Layouts
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Process Layouts

• Used in project and batch manufacturing
  (intermittent processes)
• Also used in department stores, offices,
  hospitals, and universities
• Able to make or sell a variety of products
• Use general purpose resources
• Less automation than in product layouts

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Process Layouts (2)

• Material handling costs per unit are higher than
  in product layouts
• Scheduling production is more complex than in
  product layouts

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Product Layouts

• Used in assembly lines and continuous
  manufacturing (repetitive processes)
• A cafeteria line is a product layout
• In manufacturing, product layouts are used to
  produce one product, or a small group of
  products, efficiently
• Uses special purpose resources
• More automation than in process layouts

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Product Layouts (2)

• Material handling costs per unit are lower than
  in process layouts
• Scheduling production is simpler than in process
  layouts

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Office Layouts

• Almost half the U. S. work force works in an
  office
• Human interaction and communication are the
  primary considerations in office layouts
• People who need to interact frequently should be
  close to each other
• One key layout tradeoff is between closeness and
  privacy

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Office Layouts (2)

• Open concept offices promote understanding and
  trust.
• A few closed rooms are needed for private
  discussions, such as personnel matters.
• Moveable walls provide flexibility to change the
  layout when needed.

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Office Layout Example3D Systems

• Hi-tech company provides equipment and
  materials for rapid product design and
  manufacturing
• Rock Hill headquarters handles product design,
  sales, training, and administration
• Open office plan
• Conference room
• Areas for informal meetings
• Product showroom for customers
• Cyber café and fitness center for employees

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Designing Cellular Layouts
Group technology is used to organize parts
into families with similar manufacturing
requirements.
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Process Flows before the Use of GT Cells
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Process Flows with the Use of GT Cells

• Cellular manufacturing is
• More efficient than a process layout
• More flexible than a product layout
• Used to produce parts in Just-in-Time
  manufacturing