The product or line layout is the basic type of layout commonly used by the food industry. Line balancing is done to analyze the net output of our production line and processing time at various steps.

1. Presented by:
Abhishek
B.Tech. Food Tech.
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2. Layout Planning
• Layout planning is planning that involves decisions about the physical
arrangement of economic activity centers needed by a facility’s various processes.
• Layout plans translate the broader decisions about the competitive priorities, process strategy,
quality, and capacity of its processes into actual physical arrangements.
• Economic activity center: Anything that consumes space -- a person or a group
of people, a customer reception area, a teller window, a machine, a workstation, a
department, an aisle, or a storage room.
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3. Objectives of facility layout
Main: smooth flow of work, material and information
Supporting objectives:
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4. Types of Layouts
• Four basic layout types consisting of:
• Process layouts - Group similar resources together
• Product layouts - Designed to produce a specific product efficiently
• Hybrid layouts - Combine aspects of both process and product
layouts
• Fixed-Position layouts - Product is two large to move; e.g. a
building
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5. Selection
Search
Analysis
Systematic Layout Planning
Muther (1961)
0 Data gathering
10 Evaluation
4 Space
requirements
5 Space
available
6 Space relationship
diagram
1 Flow 2 Activities
3 Relationship
diagram
7 Reasons to
modify
8 Restrictions
9 Layout alternatives
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6. Used for Repetitive or Continuous Processing
Product Layout
N. Ramesh(2014)
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7. Advantages of Product 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
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8. Disadvantages of Product 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
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9. Designing Line-Flow Layouts
• Line balancing is the assignment of work to stations in a line so as to achieve the
desired output rate with the smallest number of workstations.
• Work elements are the smallest units of work that can be performed
independently.
• Immediate predecessors are work elements that must be done before the next
element can begin.
• Precedence diagram allows one to visualize immediate predecessors better; work
elements are denoted by circles, with the time required to perform the work shown
below each circle.
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10. Cycle Time
Cycle time is the maximum time allowed at each
workstation to complete its set of tasks on a unit.
tmax < Cycle time < ∑t
Wiley 4th edition, 2004
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11. Determine the Minimum Number of Workstations Required
Theoretical Nmin is not necessarily will be the Nactual. The latter is affected by
other technical and practical considerations, too. Nmin ≤ Nactual
(rounded up to the next integer)
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12. A diagram that shows elemental tasks and their
precedence requirements.
A simplified precedence
diagrama b
c d e
0.1 min.
0.7 min.
1.0 min.
0.5 min. 0.2 min.
Precedence Diagram
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13. Efficiency %= 100 x (1 – Percentage of idle time)
Calculate Percent Idle Time and efficiency
Wiley 4th edition, 2004
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14. Designing Product Layouts – con’t
Step 1: Identify tasks & immediate predecessors
Step 2: Determine output rate
Step 3: Determine cycle time
Step 4: Compute the Theoretical Minimum number of
Stations
Step 5: Assign tasks to workstations (balance the
line)
Step 6: Compute efficiency, idle time & balance delay
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15. Step 1: Identify Tasks & Immediate Predecessors
Example 10.4 Vicki's Pizzeria and the Precedence Diagram
Immediate Task Time
Work Element Task Description Predecessor (seconds
A Roll dough None 50
B Place on cardboard backing A 5
C Sprinkle cheese B 25
D Spread Sauce C 15
E Add pepperoni D 12
F Add sausage D 10
G Add mushrooms D 15
H Shrinkwrap pizza E,F,G 18
I Pack in box H 15
Total task time 165
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16. Layout Calculations
• Step 2: Determine output rate
• Vicki needs to produce 60 pizzas per hour
• Step 3: Determine cycle time
• The amount of time each workstation is allowed to complete its tasks
• Limited by the bottleneck task (the longest task in a process):
 
 
sec./unit60
units/hr60
sec/min60min/hr x60
units/hroutputdesired
sec./daytimeavailable
)(sec./unittimeCycle 
hourperpizzasorunits/hr,72
sec./unit50
sec./hr.3600
timeneck taskbottle
timeavailable
outputMaximum 
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17. Layout Calculations con’t
• Step 4: Compute the theoretical minimum number of stations
• TM = number of stations needed to achieve 100% efficiency (every second is
used)
• Always round up (no partial workstations)
• Serves as a lower bound for our analysis
 
stations3or2.75,
nsec/statio60
seconds165
timecycle
timestask
TM 

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18. Layout Calculations con’t
• Step 5: Assign tasks to workstations
• Start at the first station & choose the longest eligible task following precedence relationships
• Continue adding the longest eligible task that fits without going over the desired cycle time
• When no additional tasks can be added within the desired cycle time, begin assigning tasks to
the next workstation until finished
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19. Last Layout Calculation
• Step 6: Compute efficiency and balance delay
• Efficiency (%) is the ratio of total productive time divided by total time
• Balance delay (%) is the amount by which the line falls short of 100%
  91.7%100
sec.60xstations3
sec.165
NC
t
(%)Efficiency 

8.3%91.7%100%delayBalance 
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20. Other Product Layout Considerations
• Shape of the line (S, U, O, L):
• Share resources, enhance communication & visibility, impact location of loading
& unloading
• Paced versus Un-paced lines
• Paced lines use an automatically enforced cycle time
• Number of Product Models produced
• Single
• Mixed-model lines
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21. A U-Shaped Production Line
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23. Thank you for your attention
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