Production operation chap 6

1. 6-1 Process Selection and Facility Layout
CHAPTER
6
Facility Layout

2. 6-2 Process Selection and Facility Layout
 Layout: the configuration of departments,
work centers, and equipment, with particular
emphasis on movement of work (customers
or materials) through the system
Facilities Layout

3. 6-3 Process Selection and Facility Layout
 Requires substantial investments of money
and effort
 Involves long-term commitments
 Has significant impact on cost and efficiency
of short-term operations
Importance of Layout Decisions

4. 6-4 Process Selection and Facility Layout
Inefficient operations
For Example:
High Cost
Bottlenecks
Changes in the design
of products or services
The introduction of new
products or services
Accidents
Safety hazards
The Need for Layout Decisions

5. 6-5 Process Selection and Facility Layout
Changes in
environmental
or other legal
requirements
Changes in volume of
output or mix of
products
Changes in methods
and equipment
Morale problems
The Need for Layout Design (Cont’d)

6. 6-6 Process Selection and Facility Layout
 Product layouts
 Process layouts
 Fixed-Position layout
 Combination layouts
Basic Layout Types

7. 6-7 Process Selection and Facility Layout
 Product layout
 Layout that uses standardized processing
operations to achieve smooth, rapid, high-
volume flow
 Process layout
 Layout that can handle varied processing
requirements
 Fixed Position layout
 Layout in which the product or project remains
stationary, and workers, materials, and
equipment are moved as needed
Basic Layout Types

8. 6-8 Process Selection and Facility Layout
Raw
materials
or customer
Finished
item
Station
2
Station
3
Station
4
Material
and/or
labor
Station
1
Material
and/or
labor
Material
and/or
labor
Material
and/or
labor
Used for Repetitive or Continuous Processing
Figure 6.4
Product Layout

9. 6-9 Process Selection and Facility Layout
 High rate of output
 Low unit cost
 Labor specialization
 Low material handling cost
 High utilization of labor and equipment
 Established routing and scheduling
 Routing accounting and purchasing
Advantages of Product Layout

10. 6-10 Process Selection and Facility Layout
 Creates dull, repetitive jobs
 Poorly skilled workers may not maintain
equipment or quality of output
 Fairly inflexible to changes in volume
 Highly susceptible to shutdowns
 Needs preventive maintenance
 Individual incentive plans are impractical
Disadvantages of Product Layout

11. 6-11 Process Selection and Facility Layout
Dept. A
Dept. B Dept. D
Dept. C
Dept. F
Dept. E
Used for Intermittent processing
Job Shop or Batch
Process Layout
(functional)
Figure 6.7
Process Layout

12. 6-12 Process Selection and Facility Layout
Work
Station 1
Work
Station 2
Work
Station 3
Figure 6.7 (cont’d)
Product Layout
(sequential)
Used for Repetitive Processing
Repetitive or Continuous
Product Layout

13. 6-13 Process Selection and Facility Layout
 Can handle a variety of processing
requirements
 Not particularly vulnerable to equipment
failures
 Equipment used is less costly
 Possible to use individual incentive plans
Advantages of Process Layouts

14. 6-14 Process Selection and Facility Layout
 In-process inventory costs can be high
 Challenging routing and scheduling
 Equipment utilization rates are low
 Material handling slow and inefficient
 Complexities often reduce span of supervision
 Special attention for each product or customer
 Accounting and purchasing are more involved
Disadvantages of Process Layouts

15. 6-15 Process Selection and Facility Layout
 Cellular Production
 Layout in which machines are grouped into a
cell that can process items that have similar
processing requirements
 Group Technology
 The grouping into part families of items with
similar design or manufacturing characteristics
Cellular Layouts

16. 6-16 Process Selection and Facility Layout
 Warehouse and storage layouts
 Retail layouts
 Office layouts
Other Service Layouts

17. 6-17 Process Selection and Facility Layout
Line Balancing is the process of assigning
tasks to workstations in such a way that
the workstations have approximately
equal time requirements.
Design Product Layouts: Line Balancing

18. 6-18 Process Selection and Facility Layout
Cycle time is the maximum time
allowed at each workstation to
complete its set of tasks on a unit.
Cycle Time

19. 6-19 Process Selection and Facility Layout
Output capacity =
OT
CT
OT operating time per day
D = Desired output rate
CT = cycle time =
OT
D

Determine Maximum Output

20. 6-20 Process Selection and Facility Layout
N =
(D)( t)
OT
t = sum of task times


Determine the Minimum Number
of Workstations Required

21. 6-21 Process Selection and Facility Layout
Precedence diagram: Tool used in line balancing to
display elemental tasks and sequence requirements
A Simple Precedence
Diagram
a b
c d e
0.1 min.
0.7 min.
1.0 min.
0.5 min. 0.2 min.
Figure 6.10
Precedence Diagram

22. 6-22 Process Selection and Facility Layout
Information Requirements:
1. List of departments
2. Projection of work flows
3. Distance between locations
4. Amount of money to be invested
5. List of special considerations
6. Location of key utilities
Designing Process Layouts