Facility Layout

Part aPart a

• Arrangement of physical facilities to optimize the interrelationships among operating personnel, material flow, information flow, and the methods required in achieving enterprise objectives efficiently, economically, and safely.

Definition (J. M. Apple)Definition (J. M. Apple)

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The Overall Objective of The Overall Objective of Facility LayoutFacility Layout

• To get the inputs (materials, supplies, etc.) into, through, and out of each facility in the shortest practicable time, at an acceptable cost.

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Objectives of Facility LayoutObjectives of Facility Layout

• Minimize material handling costs• Utilize space efficiently• Utilize labor efficiently• Eliminate bottlenecks• Facilitate communication and interaction between

workers, between workers and their supervisors, or between workers and customers

• Minimize investment in equipment

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• Reduce manufacturing cycle time or customer service time • Eliminate waste or redundant movement• Facilitate the entry, exit, and placement of material, products,

or people• Incorporate safety and security measures• Promote product and service quality• Encourage proper maintenance activities• Provide a visual control of operations or activities• Provide flexibility to adapt to changing conditions• Provide for employee convenience, safety, and comfort

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• Process Layout (or Lot Production)–machines grouped by process they perform

• Product Layout (or Continuous Production)–linear arrangement of workstations to produce a specific product

• Fixed Position Layout–used in projects where the product cannot be moved

Basic Types of LayoutsBasic Types of Layouts

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Hybrid LayoutsHybrid 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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Manufacturing Process LayoutManufacturing Process Layout

L

L

L

L

L

L

L

L

L

LM

M

M

M

D

D

D

D

D

D

D

D

G

G

G

G

G

G

A A AReceiving andShipping Assembly

Painting Department

Lathe DepartmentMilling

Department Drilling Department

Grinding Department

P

P

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Service Process LayoutService Process Layout

Women’s lingerie

Women’s dresses

Women’s sportswear

Shoes

Cosmetics and jewelry

Entry and display area

Housewares

Children’s department

Men’s department

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A Product LayoutA Product Layout

InIn

OutOut

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Comparison Of Product And Comparison Of Product And Process LayoutsProcess Layouts

PRODUCT LAYOUTPRODUCT LAYOUT PROCESS LAYOUTPROCESS LAYOUT

1. Description Sequential arrangement Functional groupingof machines of machines

2. Type of Process Continuous, mass Intermittent, job shopproduction, mainly batch production,

assembly mainly fabrication3. Product Standardized Varied,

made to stock made to order4. Demand Stable Fluctuating5. Volume High Low6. Equipment Special purpose General purpose7. Workers Limited skills Varied skills

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Comparison Of Product And Comparison Of Product And Process LayoutsProcess Layouts

PRODUCT LAYOUTPRODUCT LAYOUT PROCESS LAYOUTPROCESS LAYOUT

8. Inventory Low in-process, High in-process, high finished goods low finished goods 9. Storage space Small Large10. Material Fixed path Variable path handling (conveyor) (forklift)11. Aisles Narrow Wide12. Scheduling Part of balancing Dynamic13. Layout decision Line balancing Machine location14. Goal Equalize work at Minimize material each station handling cost15. Advantage Efficiency Flexibility

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Designing Process LayoutsDesigning Process Layouts

• Minimize material handling costs

• 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 DiagrammingBlock Diagramming

• Create load summary chart• Calculate composite (two way) movements• An Approach: Develop trial layouts minimizing

number of nonadjacent loads

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Block Diagramming Block Diagramming ExampleExample

LOAD SUMMARY CHARTDEPARTMENT

DEPT. 1 2 3 4 51 100 502 200 503 60 40 504 1005 50

60

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Initial & Final DesignsInitial & Final Designs

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Block DiagramsBlock Diagrams

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Example 1Example 1

A warehouse processes six different products monthly: a, b, c, d, e, and f. Two alternative layouts for the warehouse are being considered, A and B: Layout A Layout B 1

3

5

Receiving (R)

5

1

4

Shipping

(S) 2

4

6

Shipping (S)

6

2

3

Receiving

(R)

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Example 1 (cont.)Example 1 (cont.)The products, their monthly production levels, their sequence of processing, and distances between processing are shown in the following table:

Product Number of Products

Processed/Month

Product Sequences

Sequence Distance for

Layout A

Sequence Distance for

Layout B A 1,000 R-1-S 70 feet 50 feet B 3,000 R-2-S 70 50 C 2,000 R-3-S 50 30 D 3,000 R-4-S 50 30 E 2,000 R-5-S 30 70 F 2,000 R-6-S 30 70

Which layout alternative minimizes the monthly warehouse travel? (Use load-distance analysis)

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Example 1: SolutionExample 1: SolutionLoad-Distance For Layout A

Load-Distance For Layout B

70000 50000210000 150000100000 60000150000 9000060000 14000060000 140000

650000 630000

SELECT LAYOUT B

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Relationship DiagrammingRelationship Diagramming

• Used when quantitative data is not available

• Muther’s grid displays preferences

• Denote location preferences with weighted lines

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Ranking System For Ranking System For DepartmentsDepartments

A - absolutely necessaryE - especially importantI - importantO - okayU - unimportantX - undesirable

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Relationship Diagramming Relationship Diagramming ExampleExample

Production

Offices

Stockroom

Shipping and Receiving

Locker Room

Toolroom

A A

A O

O

OO

O

U

U U

U

EX

I

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Original LayoutOriginal Layout

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Revised LayoutRevised Layout