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Systematic Layout Systematic Layout y yPlanning
y yPlanning
References1 Richard L Francis Facility Layout and1. Richard L. Francis, Facility Layout and
Location: An Analytical Approach
2 S K Sharma Industrial engineering and2. S.K. Sharma, Industrial engineering and
operations management.
3 Daniel Kitaw Industrial Management and
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3. Daniel Kitaw, Industrial Management and
Engineering Economy.
SYSTEMATIC LAYOUT PLANNING (SLP)SYSTEMATIC LAYOUT PLANNING (SLP)
The most popular approach used in designing
l t l tplant layout.
Th p d h s b n ppli d t The procedure has been applied to
production, transportation, storage,pro uct on, transportat on, storag ,
supporting services, and office activities,
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among others.
f h
CONT’D CONT’D Information gathering Flow analysis + Activity analysis Relationship diagram
Space consideration + Relationship diagram Space consideration + Relationship diagram Space relationship diagram
Modifying consideration + Practical limitation A number of alternative layouts are designed and
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y gevaluated
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INFORMATION GATHERING INFORMATION GATHERING
Information is required pertaining to the
d t d h d lproduct, process, and schedule.
D t di p d t d si d isi s Data regarding product design decisions can
affect the layout significantly.affect the ayout s gn f cant y.
The product design decisions can directly or
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p g yindirectly affect the layout.
Basic product design data can be obtained formCONT’D CONT’D
Basic product design data can be obtained form
photographs of the product, exploded drawings,
engineering drawings of individual parts, parts lists,
bill of materials and assembly chartsbill of materials and assembly charts.
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CONT’D CONT’D
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CONT’D CONT’D
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CONT’D CONT’D Company open-close valve company Prepared by Jhon Mc Franciesp y p p y p y J F
Product gate valve Date October 31, 19xx
Part No.
PartName
Drawing No.
No. Unit Materials Size Make Buy
0105 Nut 2005 1 Brass Buy0105 Nut 2005 1 Brass Buy
0204 Washer 2003 1 Aluminum 0.8”odx0.22”idx0.01” thick Buy
0303 Handle 1010 1 Zinc, die casting 2.0”x0.6” Make
0501 Cap 1008 1 Brass, hex bar stock 0.75”x0.40” Make
0601 Packing 2001 1 Rubber 0.58”odx0.25”idx0.25” Buy
0702 Ferrule 1007 1 Brass, tube 0.4”x0.2” Make
0802 Stem 1000 1 Brass, rod 3.0”x0.375” Make
0901 B hi 1004 1 B 1 1” 1 5” M k0901 Bushing 1004 1 Bronze 1.1”x1.5” Make
1001 Gasket 2007 1 Rubber 1.4”odx1.17”idx0.025” Buy
1101 Gate 1006 1 Bronze 1.2”x0.96”x0.55” Make
1305 Body 1002 1 Bronze 1.4”x1.9”x2.125” Make
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1402 Box 2011 1 Cardboard 2.125”x2.125”x4.25” Buy
1503 Staple 2012 4 Aluminum Buy
1603 Label 2013 1 Adhesive backed paper 2.0”x1.0” Buy
Company open-close valve company Prepared by Jhon Mc Francies
Product gate valve Date October 31, 19xx
Level Part No. Part Name Drawing No. No. Unit Make Buy Comments
0 0010 Pipe valve 0010 1 Make0 0010 Pipe valve 0010 1 Make
1 0100 Bottom assembly 0020 1 Make
2 0200 Top assembly 0030 1 Make
4 0105 Nut 2005 1 Buy
3 0204 Washer 2003 1 Buy
2 0303 Handle 1010 1 Make
3 0403 Paint - 0.010 oz. Buy
4 0501 Cap 1008 1 Make
5 0601 Packing 2001 1 Buy
3 0702 Ferrule 1007 1 Make
1 0802 Stem 1000 1 Make
2 0901 Bushing 1004 1 Make2 0901 Bushing 1004 1 Make
3 1001 Gasket 2007 1 Buy
2 1101 Gate 1006 1 Make
2 1201 Grease - 0.001 oz. Buy
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3 1305 Body 1002 1 Make
6 1402 Box 2011 1 Buy
7 1503 Staple 2012 4 Buy
7 1603 Label 2013 1 Buy
CONT’D CONT’D
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CONT’D CONT’D ♦ The assembly chart is an analog model of the
operations and inspections required in assembling ap p q g
product.
♦ Assembly chart shows graphically which parts must
go into(or be assembled to) other partsgo into(or be assembled to) other parts.
♦ The assembly chart is the basis for the layout of the
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y y
assembly department or assembly lines.
CONT’D CONT’D ♦ Process design decisions determine whether a part
will be purchased or produced, how the production ofp p , pparts will be achieved, what equipment will be used,
d h l ll k f hand how long it will take to perform the operation.
♦ Such information is typically summarized on an♦ Such information is typically summarized on an
operation sheet or route sheet.
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CONT’D CONT’D C P d b J M FCompany open-close valve company Prepared by Jhon Mc Francies _ _
Product gate valve Date October 31, 19xx _
Part name Bushing Part Number 0901 _
Material Bronze casting Production Quantity 1500 _
Op. No. Op. Description Machine type Tooling an d supplies Setup time (hrs) Op. time
05 Cast: using green sand mold with 50 bushingsper mold; pour, cool, cut off gates and risers
Bench moldBand saw
T- shaped dry sand core for each bushing
0.50 2.00
06 Clean: grind, as needed to remove flashing, and tumble
Bench or pedestal grinder; tabling barrel
A-24-M-8-V type grinding wheel
0.25 0.75 and tumble grinder; tabling barrel grinding wheel
07 Drill hole:3/16”x1/2” Turret lathe 3/16” drill 0.50 2.5o
08 Bore hole: 7/16”x1/4” Turret lathe 7/16” bore - 2.75
09 Turn: small end to 5/8” large end to 3/2” and then large end to 5/4”
Turret lathe Round-nose turning tool, cut off tool and right hand
- 10.50then large end to 5/4 cut-off tool and right-hand
facing tool
10 Thread: small and large ends (5/8”-16 UNC-2A and 5/4”-16 UNC-2A threads)
Turret lathe Stationary, self-opening die heads for 5/8” and 5/4”
- 9.25
T t l 1 25 27 75
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Total 1.25 27.75
Comments: Operations 7 through 10 are performed on the same turret lathe, using one setup. The operating times given include rechecking the work piece. The operations are performed as follows: chuck large end; drill, bore, turn, thread, and cutoff small end to length; chuck small end, grip hexagonal surface; turn large end to 1.50” over 0.375” length, cutoff to length, turn large end to 1.25” over 0.25” length, retaining 1.50” diameter over 1.25” length.
CONT’D CONT’D ♦ The operation process chart is often used to
supplement the route sheet; in a sense, it is a pictorialpp , p
representation of the route sheet.
♦ Its an expansion of the assembly process chart in that
it includes all operations and inspections performed onit includes all operations and inspections performed on
the product.
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♦ The basis for the layout of a manufacturing plant.
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♦ A precedence diagram establishes the prerequisite
CONT’D CONT’D ♦ A precedence diagram establishes the prerequisite
assembly steps that must be completed beforeperforming a given assembly step.perform ng a g ven assembly step.
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CONT’D CONT’D
♦ Schedule design decisions tell us how much to produce
and when to produceand when to produce.
♦ Production schedules are given using an analog modelg g g
called Gantt chart.
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CONT’D CONT’D
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CONT’D CONT’D ♦ Most information sources available portray yesterdays
and, possibly today’s data., p y y
♦ We are interested in tomorrow's data, since we are
developing a solution to be used tomorrow.
D h i h i l i hi♦ Data sources emphasizes the interrelationships among
product, process, schedule, and layout design.
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p p y g
♦ The layout must support the objectives of the facility.
CONT’D CONT’D ♦ The effective arrangement of personnel and
equipments depends on accurate information regardingq p p g g
product, process, and schedule requirements.
♦ When such requirements change rapidly, it is
important for the layout to accommodate changes inimportant for the layout to accommodate changes in
requirements.
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FLOW ANALYSIS AND ACTIVITY ANALYSISFLOW ANALYSIS AND ACTIVITY ANALYSIS
Flow analysis concentrates on some
tit ti f t b tquantitative measures of movement between
departments or activities.departments or activities.
Activity analysis is concerned with the non- ct ty ana ys s s concerned w th the non
quantitative factors that influence the
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location of departments or activities.
CONT’D CONT’D
♦ Basic data have been obtained concerning the process,
d t d s h d l th l t l st is i sitiproduct and schedule, the layout analyst is in position
to analyze the flow of materials, equipment, and
personnel.
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Factor that affect the flow pattern given by Apple:
CONT’D CONT’D Factor that affect the flow pattern given by Apple:
1. External transportation facilities2. Number of parts in product3. Number of operations on each part4. Sequence of operations on each part5. Number of subassemblies5. Number of subassemblies6. Number of units to be produced7 Necessary flow between work areas
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7. Necessary flow between work areas8. Amount and shape of space available
9 Influence of process
CONT’D CONT’D 9. Influence of process10. Types of flow pattern11 P d f l11. Product versus process type of layout12. Location of service areas13. Production department location14. Special requirement of departmentsp q p15. Material storage16 Desired flexibility
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16. Desired flexibility17. The building
T f Fl P
CONT’D CONT’D Types of Flow Patterns
♦ Flow patterns can be classified either horizontal or♦ Flow patterns can be classified either horizontal or
vertical.
♦ There are at least five basic types of horizontal flow
ttpatterns.
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CONT’D CONT’D
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CONT’D CONT’D
♦ Vertical flow pattern exist both in single-story and
multistory buildings. Utilization of overhead space has
focused great attention on the design of vertical flowf g g f f
pattern.
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CONT’D CONT’D
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T f l
CONT’D CONT’D Types of layout
♦ The choice of layout type is the factor affecting the♦ The choice of layout type is the factor affecting the
flow pattern.
♦ There are four general types of layout categories:1 P d t l t1. Product layout2. Process layout3 F d d
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3. Fixed position and,4. Combination layout
Fl l h
CONT’D CONT’D Flow analysis approach
♦ Flow process chart♦ Flow process chart
♦ Multiproduct process chartp p
♦ Flow diagram
♦ From-to-chart
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CONT’D CONT’D
Flow process chart
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CONT’D CONT’D
Multiproduct process chart
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CONT’D CONT’D
Flow diagram
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CONT’D CONT’D
4 - 35From-to-chart
ACTIVITY RELATIONSHIP ANALYSIS ACTIVITY RELATIONSHIP ANALYSIS
• Flow analysis tends to relate various activities on some
quantitative basisquantitative basis.
• Typically, the relationship is expressed as a functionyp y, p p
of transport cost or material handling cost.
• There might be other qualitative aspects of layout
design that might be important
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design that might be important.
CONT’D CONT’D l h hRelationship chart
• A relationship chart is a triangular matrix whoseA: Absolutely necessary• A relationship chart is a triangular matrix whose
elements represent the relationships among plant
y y
E: Especially important
I: Importantlayout departments.
L tt d l d t t d i bl
I: Important
O: Ordinary closeness OK
• Letter codes are also used to represent desirable or
undesirable levels of closeness between departments.
U: Unimportant
X: Undesirable
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p
Th l h h (REL h )
CONT’D CONT’D • The activity relationship chart (REL chart) was
developed to facilitate the consideration of qualitativep q
factors – analytically!
• The REL chart replaces the numbers in the Travel
chart by a qualitative closeness ratingchart by a qualitative closeness rating.
• All pairs of relationships are evaluated, and a closeness
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rating (A, E, I, O, U, and X) is assigned to each pair.
CONT’D CONT’D
• With the exception of U rating, the reason for the
assigned rating is indicated using a numeric code.
• Closeness ratings represent an ordered preference
for “closeness”.
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CONT’D CONT’D
• Specifically, A and X ratings are considered to be
most important ratingsmost important ratings.
• Hence, any layout must satisfy A and X ratings.Hence, any layout must satisfy A and X ratings.
• Thus, A and X > E > I > O > U , where > means “more
important or higher ranking than.”
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Rule of thumb:
CONT’D CONT’D Rule of thumb:
• Very few A and X relationships should be assigned.( th 5% f th l ti t b A(no more than 5% of the closeness ratings to be an Aand X).N h 10% h ld b E• No more than 10% should be an E.
• No more than 15% to be an I.• No more than 20% to be an O.• Which means that about 50% of the relationships
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Which means that about 50% of the relationshipsshould be U.
Bl k l bl k l t d l d fi t b
CONT’D CONT’D • Block plans, or block layouts are developed first by
determining the sizes, shapes and relative locations of
departments or other designated activities.
• Next, detailed layouts are designed for each
departmentdepartment.
• Thus different REL charts are needed for designing
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block plans and detailed layouts.
CONT’D CONT’D
• The process of constructing an activity relationship
chart can be complicated by the presence of multiple
relationships that will influence the design of the
layout.
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CONT’D CONT’D
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CONT’D CONT’D
• The relationship chart and the numerically weightedratings, assigned to the closeness values, are the basisrat ngs, ass gned to the closeness alues, are the bas s
for the order and placement in which departments
enter the layout.
• The ratings assigned for A E I O U and X are used to• The ratings assigned for A,E,I,O,U and X are used to
calculate the Total Closeness Rating (TCR) for each
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department.
CONT’D CONT’D
m ... 1 = i );rV( = TCR ij
n
1=ji
Where
1=j
TCRj = Total Closeness Rating for department;
V(rij) = Numerical value assigned to the closeness value for
department i and j.
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n = Total number of departments.
CONT’D CONT’D
• The first department to be placed in the layout is
assigned by taking the department with the greatestassigned by taking the department with the greatestTCR.
• Next, the relationship chart is scanned to see if there
i d t t th t h A l ith this any department that has an A value with the
department already placed.
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CONT’D CONT’D
• If no A value exists, a check is made for E value, and
if no E value appears a check is made for I valueif no E value appears, a check is made for I value,
followed by O value.
• If ties develop, the department having the greatest
TCR i h Thi i i ll d ilTCR is chosen. This process is continually used until
finally all departments are placed in the layout.
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y p p y
Example Example
Numerical values
A = 10,000; E = 1,000;I = 100; O = 10; U = 0; andX = -10,000
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CONT’D CONT’D
a dcb
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CONT’D CONT’D
hh
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REL DiagramCONT’D CONT’D
REL Diagram
• From REL chart, we construct activity relationshipy p
diagram (REL diagram).
• The purpose is to depict spatially the relationships of
the activitiesthe activities.
• The basic premise is that geographic proximity can be
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used to satisfy particular relationships.
CONT’D CONT’D
• For example, when the activity relationships reflect
the magnitudes of material flows pairs of activitiesthe magnitudes of material flows, pairs of activities
having the greatest pair wise flow are located next to
each other.
Si il l i f i i i h i A i• Similarly, pairs of activities having an A rating are
located adjacently.
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j y
CONT’D CONT’D
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SPACE REQUIREMENT AND AVAILABILITY SPACE REQUIREMENT AND AVAILABILITY
The bases for determining the space requirement:
i. Production rate
ii E ipm nt i m ntii. Equipment requirement
iii.Employee requirementiii.Employee requirement
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Commonly used methods of determining space
CONT’D CONT’D Commonly used methods of determining space
requirement:
i. Production center method
• Consists of a single machine plus all the associated
equipment and space required for its operationsequipment and space required for its operations.
• Work space, maintenance space, and storage space
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p , p , g p
are added to space requirement for the machine.
CONT’D CONT’D
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ii Roughed out layout method
CONT’D CONT’D ii. Roughed-out layout method
• Templates or models are placed on the layout top p y
obtain an estimate of the general configuration and
space requirements.
iii Space standards methodiii. Space standards method
• Industry standards can be used to determine the
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y
space requirement.
CONT’D CONT’D
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D i i th l ti hi di
DESIGNING THE LAYOUT DESIGNING THE LAYOUT Designing the space relationship diagram
• The over all layout is designed by first combining theThe over all layout is designed by first combining the
space consideration with the REL diagram.
• For each activity, a space template is constructed, to
scale t represent the size and shape f the activityscale, to represent the size and shape of the activity.
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ExampleExample
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CONT’D CONT’D
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• After construction the space relationship diagram the
CONT’D CONT’D • After construction the space relationship diagram, the
space templates are modified and adjusted and the
relative locations of the activities are shifted as
necessary to accommodate practical limitations andnecessary to accommodate practical limitations andother considerations.
• The block plan is a scaled diagrammatic representation
f th b ildi ll h th l ti f i t l4 - 63
of the building normally shows the locations of internalpartitions and columns.
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CONT’D CONT’D Presenting the layout
• A number of alternative component designs a number• A number of alternative component designs, a number
of alternative overall designs, or a number of
alternative detailed designs should have been
generatedgenerated.
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CONT’D CONT’D
There are three methods of visually representing layouts
• Drawing or sketches
T di si l i i d ls• Two-dimensional iconic models
• Three-dimensional iconic modelsThree dimensional iconic models
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CONT’D CONT’D
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CONT’D CONT’D Selection, implementation and follow-up
• Select the design from alternatives which best meets• Select the design from alternatives which best meets
your objective.
• The design selected must be specified, all concerned
b ld d h l b i ll dmust be sold, and the layout must be installed,
observed, and periodically evaluated in an operating
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p y p g
environment.