3 facility layout

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3 facility layout

  1. 1. Facility LayoutDr. Everette S. Gardner, Jr.
  2. 2. Machine shop process layout Receiving Grin- Mills ders Raw matl. Large number of storage Assem- low volume bly products Drills Planers Finished Inspec- goods Lathes Automatics tion storage Part A Part B Facility Layout 2
  3. 3. Product layout Raw matl. FabricationRec- storage line-part Beiving Fabrication Planer line-part A Finished Lathe goods Drill Small number storage Mill of Mill high volume Drill products Grinder Mill Assembly line Automatic Facility Layout 3
  4. 4. Possible solutions to the processlayout problem6 Department problem has 6! or 720 possible solutions: A B C D E F I.E., there are 720 different arrangements of the 6 departments on the 6 locations on the grid. Facility Layout 4
  5. 5. Possible solutions to the processlayout problem (cont.)Problem complexity grows exponentially:Nbr. depts. Solutions 10 3,628,800 15 1.31 x 10^12 20 2.43 x 10^18 50 3.04 x 10^64 Facility Layout 5
  6. 6. Solutions considered by Craft• N! solutions to problem with N depts.• Craft considers only N(N-1) pairs of exchanges, 2 starting with each dept. Facility Layout 6
  7. 7. Craft initial layout of furniture plant A B C D E F G I H J TOTAL COST = $2524.68 Facility Layout 7
  8. 8. Craft final layout A E C I G F B H J D TOTAL COST = $766.68 Facility Layout 8
  9. 9. Synopsis of assembly line balancing1. Set up a precedence table.2. Compute required cycle time: C = (production time) / (required output in units)3. Compute minimum cycle time: CMIN = time for longest task4. Compute minimum number of stations : SMIN = (sum of all times) / C Facility Layout 9
  10. 10. Synopsis of assembly linebalancing (cont.)5. Select rule by which tasks are assigned to work stations. Examples: (1) select tasks with longest operation times first or (2) select tasks with largest number of following tasks first6. Assign tasks to the first work station until the sum of the task times are equal to the cycle time, or no other tasks are feasible. Repeat for stations 2, 3, … until tasks are assigned.7. Evaluate the efficiency of the balance: E = (sum of all times) / (actual nbr. of stations x C) Facility Layout 10
  11. 11. Line balancing quiz 0.4 B 0.3 1.1 1.1 0.5 E G 0.7 0.3 A C I J 1.2 0.4 0.8 D F HBalance this production line to achieve an output of 367 units perday. Available production time is 8 hrs. less a 40 min. lunch break.Use the largest number of following tasks rule to select tasks forwork stations. Break ties with the longest operation time. Facility Layout 11
  12. 12. Multiple solutions in line balancing 6 B 4 F 7 3 C 5 A H 5 5 D G 2 E Facility Layout 12
  13. 13. Multiple solutions in line balancing(cont.) 84 Number of solutions 25 3 1 2 3 4 5 6 7 Stations Facility Layout 13
  14. 14. Volvo layouts Rotating round table with definite cycle time -- facilitates teamwork Facility Layout 14
  15. 15. Volvo layouts (cont.) Horseshoe conveyor sections to enable worker communications Facility Layout 15
  16. 16. Volvo layouts (cont.) Interim storage Storage areas to separate line into definite supervisory groups Supervisor Supervisor B A Facility Layout 16
  17. 17. Volvo layouts (cont.) Machines grouped in banks of 3 so workers can exchange jobs and assist each other in set-up Facility Layout 17
  18. 18. Volvo continued E S S E S S E S SConnections of subassembly islands feed parts/components toend-assembly islands—each island functions as a separate team Facility Layout 18

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