Hybrid Layouts

Hybrid Layouts

Cellular LayoutsBy Maria Roig

Hybrid Layouts

Hybrid layouts modify and/or combine some aspects of product and process layouts.

Three hybrid layouts: Cellular layouts (presented by Maria Roig)

Flexible manufacturing systems (presented by Brian Barnes)

Mixed-model assembly lines (presented by Brian Barnes)

Hybrid Layouts: Cellular layouts

Cellular layouts group dissimilar machines into work centers (called cells) that process families of parts with similar shapes or requirements.

Combines the flexibility of a process layout with the efficiency of a product layout.


Characteristics of the process:

Cells are arranged in relation to each other so that material material movement is minimizedmovement is minimized.

Large machines that cannot be split among cells are located nearlocated near to the cells that use them (point of use)

The layout of machines within each cell resembles a small assembly line.assembly line.

AdjustmentsAdjustments can be used to arrange the machines within the cell.

Computer programs can be used to locate cells.


Example:

Machines are grouped by function into four distinct departments.

Component parts manufactured in the process layout section of the factory are later assembled into a finished product on the assembly line.

The parts follow different flow paths through the shop. Three representative routings, for parts A, B, and C. Workers are skilled within a single department and can

operate more than one machine at a time.


Notice:The distancedistance that each part must travel before

completionthe irregularityirregularity of the part routingsAmount of “paperwork”“paperwork” needed to direct the flow of

each individual part and to confirm that the right operation has been performed

Original Process Layouts


In its current form, there is no apparent pattern to the routings.

PRODUCT FLOW ANALYSIS (PFA) reorders part routing matrices to identify families of parts with similar processing requirements.

If we reorder the matrix listing which parts have four machines in common, three...Part Routing Matrix


Part Routing Matrix Reordered to Highlight Cells

Revised Layout with Three Cells


Advantages: Reduced material handling

and transit time Reduced setup time Reduced work-in-process

inventory Better use of human

resources multifunctional workers

Easier to control Easier to automate

Disadvantages: Inadequate part families Poorly balanced cells Expanded training and

scheduling of workers Increased capital

investment


Questions?

Documents

Hybrid Layouts