1. Report TO MAXIMIZE
EFFECIANCY OF FACILITY
Prepared by
Ahmad Alshehri
Brayan Pereira
Prepared For
BeYouTiful SALON SPA SUPPLY
June 4, 2014
2. 1
TABLE OF CONTENTS
PAGE
Abstract …………........…………………………………………………..…… 1
Introduction ………………………….…………….………………….….…… 2
Data Collection ……...………………………….…………………….....……. .2
Analysis ……………………………………….….………..……………….….. 3
Final Design……………...…………….……………………….………………3
Conclusion ……………...………………………………………………..……..4
Appendices ……………………………………………………………………..5
3. 1
ABSTRACT
The current layout of BeYouTiful salon was found to be ineffective when it comes to
travel time between stations. To remedy this, a new layout was designed using a layout
design method. The new layout was made and found to be an improved solution. This layout
also takes into account the stations that cannot be moved feasibly, while at the same time
incorporating the owner’s desire to have a central desk.
4. 2
INTRODUCTION
The purpose of report is to illustrate the merits of redesigning BeYoutiful Salon Spa Supply’s
current facility. This introduction highlights the need for redesign.
Currently, BeYoutiful is very popular amongst the local population. It currently enjoys
positive reviews from the review website Yelp. In the last three months reviews and check-ins
for this location have increased by around 10%. This indicates a possible increase in customer
presence at peak hours (Thurs 4-6, Fri 4-6).
Stores with high volume of customers must be very accessible. Space must be used
efficiently to maximize walking/free space. The layout must also be easy to understand to avoid
customers walking without direction, which causes congestion and an uncomfortable
atmosphere.
Presently, BeYoutiful’s layout can be confusing to understand. This is mostly due to having
two widely used entrances. Customers entering from the door by Foothill Blvd. must walk the
length of the store to find the front desk. Additionally, shelves and products block the view of the
desk from that entrance, thus making it difficult to locate. Furthermore, products are scattered
throughout the store. This would require a customer to walk between all services to view all the
products that this location has to offer (see Appendix A).
Data Collection
Since our main focus was to redesign the layout for the salon, it was decided to employ a
basic layout design method. The approach, which is outlined in the book “Manufacturing
Facilities: location, planning, and design”, determines the location of certain stations based on
travel frequency between said stations. Since there are too many combinations of possible
customers for this salon, only the top five customers and their frequency of travel between
stations are considered. Based on sales the top five customers are as follows:
1. Customer sits in the waiting area, gets a haircut, nails are done, shops for products
and then pays
2. Customer sits in the waiting area, gets nails done and then pays
3. Customer shops for products and then pays
4. Customer sits in the waiting area, gets a haircut, does a facial/wax , receives a
massage and then pays
5. Customer sits in the waiting area, gets a haircut, receives hair coloring treatment, hair
is dried and then pays
In this situation, each area that is used by a customer is assigned a letter (see Appendix
B). Using this notation a simplified view of the top five customer’s path can be obtained:
1. WaHcNaSaFd
2. WaNaFd
3. SaFd
4. WaHcFwTrFd
5. WaHcCtDFd
5. 3
The trips per month were determined by extrapolating values of each type of customer
throughout a week. Customer 1: 100 trips per month, customer 2: 40 trips per month, customer 3:
20 trips per month, customer 4: 10 trips per month, customer 5: 5 trips per month.
ANALYSIS
Using our basic layout method, the From-To chart and total flow chart were constructed
(Appendix B).
From this it was determined that an “A” (absolutely necessary) relationship would be a
value of 120, “E” (especially necessary) would be 100, “I” (Important) would be 40, “O”
(Ordinary) would be 10, and “U” (Unimportant) would be 0. From this a relationship chart was
constructed (Appendix B).
From this relationship chart, two different node diagrams were constructed in order to
have more than one redesigned layout (Appendix C). Also for comparison, a node diagram for
the current layout was constructed (Appendix E).
Using these node diagrams and knowing, after measuring during our visits to the facility,
the square footage, three grid layouts were constructed (Appendix C). The total square footage of
the location is measured at 3500 sq ft. The stations were measured to be in the sizes shown in
appendix B. Grid blocks that equal 100 sq ft were used, thus making the area 7 x5 blocks.
Using these three grid layouts the effectiveness chart of each layout was determined and
shown below. This takes into account the relationship value and distance between stations by
block count. A lower effectiveness value is desirable (Appendix D & E).
As you can see the two new layouts have an effectiveness value of 3 and 6 respectively,
while the current layout has an effectiveness value of 38. This suggests that the new redesigned
layouts are superior to the current layout when it comes to minimizing travel time for
customers/employees between stations.
FINAL DESIGN
Now the decision is between the two new redesigned layouts. Immediately when
examining the layouts a problem arises. Both layouts require major restructuring of the facility.
Both layout 1 and layout 2 require the movement of both the facial/wax room and the therapy
room. This would require tearing down walls and relocating the rooms. This endeavor would be
very costly and thus not recommended. Another pressing issue is the fact that both redesigns
require the movement of the color treatment area. Since this area requires sinks and thus
plumbing, any movement of this location will cause a high increase in cost.
At this point in our report we consulted with the owner to talk about our redesigns. She
coincided with us that movement of the facial/wax room and the therapy room would be though
and that it should be avoided. On the movement of the color treatment area the felt like it would
be though but doable. This suggested that she was not looking to move it, but if needed to she
would. She then also requested that the front desk be in the middle of the shop, since she has two
widely used entrances. Taking in all the feedback and the analysis of proposed layouts we are
now able to continue our report.
Keeping in mind that facial/wax room and the therapy room should not be moved, while
knowing the coloring treatment is desired to stay in its original location, a new layout was made.
This new layout (Appendix F) has a nodal and grid diagram as well as an efficiency calculation.
6. 4
As you can see the desk was place in the middle while we left the facial/wax room and therapy
room in the same location. Luckily we were able to place the coloring treatment station in the
same location as well. This layout not only addresses the concerns of cost from the previous
layouts, but also incorporates the owner’s desires to have a central desk. Of course this relocation
of areas caused the effectiveness score to go up, but to a manageable value of 9. All this being
said it is clear that the third and final layout is the best choice for BeYoutiful Salon.
CONCLUSION
From the analysis it was determined that the current layout is not effective when it comes
to travel time between stations. Then by using a basic layout method, which optimizes travel
time between stations, two new layouts were designed. Both layouts saved travel time, but did
not take into account that certain stations are too costly to move. Therefore, a third layout was
designed that took into account what stations were stationary, while also meeting the owner’s
needs to have a central desk. However, importantly this third layout’s effectiveness score only
went up by three, which is still substantially less than the original layout’s score of 38. This third
layout not only incorporates a central desk but also makes the layout of the design easier to
understand for the customers. To fully accomplish this layout a circular ergonomic desk must be
purchased, but other than that everything thing else is a simple movement of stations. We also
recommend the installation of adjustable sinks. This sinks protect the employees from bending
over when washing hair, which will reduce injuries. The ergonomic mats for the stylist should
also be replaced because they are getting old and inefficient.
8. 6
Appendix B
Flow/Relationship Chart
Hc Ct Na D Fw Tr Fd Sa Wa Sum
Hc - 5(O) 100(E) 10(O) 115(A) 230
Ct - 5(O) 40(I) 50
Na - 40(I) 100(E) 240
D - 5(O) 10
Fw - 10(O) 20
Tr - 10(O) 20
Fd - 120(A) 175
Sa - 220
Wa - 155
Wa = Waiting Area = 300 sq ft
Hc = Hair Cut = 600 sq ft
Na = Nails = 200 sq ft
Sa = Shopping Area = 800 sq ft
Fd = Front Desk = 300 sq ft
Fw = Facial/Wax = 300 sq ft
Tr = Therapy Room = 300 sq ft
Ct = Color Treatment = 400 sq ft
D = Dryer = 300 sq ft
To-From Chart
Hc Ct Na D Fw Tr Fd Sa Wa
Hc - 5 100 10
Ct - 5
Na - 40 100
D - 5
Fw - 10
Tr - 10
Fd -
Sa 100, 20 -
Wa 100 ,
10, 5
40 -
9. 7
Appendix C
Grid 2
Sa Sa Sa Sa Fd
Sa Sa Sa Sa Fd
Hc Hc Na Na Fd
Hc Hc Hc Hc Tr
Wa Wa Wa Tr Tr
Ct D D D Fw
Ct Ct Ct Fw Fw
Grid 1
Fw Fw Tr Wa Wa
Fw Hc Tr Tr Wa
Hc Hc Hc Ct Ct
Hc Hc Na Ct Ct
Sa Sa Na Fd D
Sa Sa Sa Fd D
Sa Sa Sa Fd D
Fw
Hc
Na
Wa
Tr
D
Sa Fd
Ct
Layout 1 Layout 2
Na
Hc
Wa
Tr
Fd
Sa
Ct D
Fw
10. 8
Appendix D
Effectiveness Chart (Layout 2)
Hc Ct Na D Fw Tr Fd Sa Wa RV
Hc - 1x1 3x0 1x2 4x0 3
Ct - 1x0 2x0 0
Na - 2x0 3x0 0
D - 1x3 3
Fw - 1x0 0
Tr - 1x0 0
Fd - 4x0 0
Sa - 0
Wa - 0
Effective: 6
Effectiveness Chart (Layout 1)
Hc Ct Na D Fw Tr Fd Sa Wa RV
Hc - 1x0 3x0 1x0 4x0 0
Ct - 1x0 2x0 0
Na - 2x0 3x0 0
D - 1x0 0
Fw - 1x0 0
Tr - 1x3 3
Fd - 4x0 0
Sa - 0
Wa - 0
Effective: 3
11. 9
Appendix E
Grid Original Layout
Tr Tr Fw Fd Fd
Tr Fw Fw Fd Wa
Ct Ct Ct Wa Wa
Ct Sa Sa Sa Sa
Na Sa Sa Sa Sa
Na D Hc Hc Hc
D D Hc Hc Hc
Effectiveness Chart (Original Layout)
Hc Ct Na D Fw Tr Fd Sa Wa RV
Hc - 1x2 3x1 1x3 4x2 16
Ct - 1x2 2x0 2
Na - 2x5 3x0 10
D - 1x5 5
Fw - 1x0 0
Tr - 1x1 1
Fd - 4x1 4
Sa - 0
Wa - 0
Effetiveness: 38
Original Layout
Ct
Na
D
Tr
Sa
Wa
Fd
Fw
Hc
12. 10
Layout 3
Fw
Hc
Na
Wa
Tr
D
Sa
Fd
Ct
Appendix F
Grid Original Layout
Fw Fw Na Na Sa
Fw Tr Hc Sa Sa
Tr Tr Hc Hc Sa
Ct Ct Fd Hc Sa
D Ct Fd Hc Sa
D Ct Fd Hc Sa
D Wa Wa Wa Sa
Effectiveness Chart (Layout 3)
Hc Ct Na D Fw Tr Fd Sa Wa RV
Hc - 1x2 3x0 1x2 4x0 4
Ct - 1x0 2x0 0
Na - 2x2 3x0 4
D - 1x0 3
Fw - 1x0 0
Tr - 1x1 1
Fd - 4x0 0
Sa - 0
Wa - 0
Effetiveness: 9
