layout

1. Facility Layout
Configuration of departments, work centres and equipment, with
particular emphasis on movement of work through the system
Two basic types of layout:
• Product
• Process
• Require substantial investment of money & effort
• Involve long term commitment
• Have significant impact on the cost and efficiency of operations
Why Important?

2. Product Layout
The work is divided into a series of standardized tasks,
permitting specialization of both labor and equipment
Facility Layout
Layout that uses standardized processing operations
to achieve smooth, rapid, high volume flow

3. Product Layout
Facility Layout

4. Advantages
• High rates of output
• Low unit cost due to high volume
• Low material handling cost per unit
• High utilization of labor & equipment
Limitations
• Repetitive work – boring & fatigue
• System is fairly inflexible
• System is highly susceptible to breakdown
Facility Layout

5. U-shaped Layouts
Facility Layout

6. U-shaped Layouts
• Compact
• Increased communication
• Flexibility in work
Facility Layout

7. Process Layout
Designed to process items or provide services that involve a
variety of processing requirements
Items are frequently moved in batches to the departments
in a sequence that varies from job to job
Layout features functional grouping where similar kinds of
activities are performed
Facility Layout

8. Process Layout
Facility Layout
X-ray Ultrasound
ECG Pathology

9. Advantages
• Can handle a variety of processing requirements
• Not particularly vulnerable to equipment failures
• General-purpose equipment is easier to maintain
Limitations
• High inventory costs for batch processing
• Routing & scheduling pose continual challenges
• Equipment utilization rates are low
• Slow material handling –also inefficient
Facility Layout

10. Facility Layout

11. X-ray
ECG Pathology
Ultrasound
Facility Layout
Group 1: X-ray, Ultrasound, ECG
Group 2: X-ray, Ultrasound
Group 3: Ultrasound, Pathology
Group 4: X-ray, ECG, Pathology
Room 1 Room 2
Room 3 Room 4

12. Cells are miniature versions of Product/Process layout
Groupings are determined by operations needed to
perform work for a set of similar items
Facility Layout
Cellular Layout
Machines are grouped into cells
Cell 1
Cell 3 Cell 4
Cell 2

13. Facility Layout
Cellular Layout

14. Fixed Position Layout
The items being worked on remains stationary, and
workers, material and equipment are moved about
Facility Layout
Weight, size, bulk or some other factor makes it
undesirable or extremely difficult to move the product

15. Facility Layout
Line Balancing
Assignment of work to stations in a line as to achieve the
desired output rate with the smallest number of workstations
The goal is to obtain workstations with well-balanced workload

16. Work
element
Time
(sec)
Predecessor
A 40 -
B 30 A
C 50 A
D 40 B
E 6 B
F 25 C
G 15 C
H 20 D, E
I 18 F, G
Line Balancing
Desired Output Rate = 2400 Units/Wk

17. Facility Layout
Steps of Line Balancing
Determine desired output rate
Calculate Cycle Time
Find Theoretical Minimum
Determine Idle Time
Calculate Efficiency
Assign Tasks to Stations
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18. Work
element
Time
(sec)
Predecessor
A 40 -
B 30 A
C 50 A
D 40 B
E 6 B
F 25 C
G 15 C
H 20 D, E
I 18 F, G
Line Balancing
A
B
C
D
E
F
G
H
I

19. Station 1 Station 3
Station 2 Station 4 Station 5
Facility Layout
B
A
D
C
F
E
H
G
I