Chaptre 2. Facility Layout Introduction Product layout Process layout Fixed position layout
Hybrid Layout
Transcript of Hybrid Layout
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Hybrid Layouts
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Hybrid Layouts
Hybrid layouts modify and/or combinesome aspects of product and process
layouts. Examples:
Group technology & manufacturing cells – used in Justin !ime manufacturing
Grocery stores
!hree hybrid layouts: "ellular layouts #presented by $aria %oig
'lexible manufacturing systems #presented by (rian(arnes
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Hybrid Layouts: "ellularlayouts
"ellular layouts group dissimilar
machines into )or* centers
#called cells that process families
of parts )ith similar shapes or
re+uirements.
"ombines the ,exibility of a process layout )iththe e-ciency of a product layout.
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Designing Hybrid Layouts One of the most popular hybrid layouts uses
Group Technology (GT) and a cellular layout GT has the advantage of bringing the eciencies
of a product layout to a process layoutenvironment
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Process Flows before the Use of
GT Cells
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Process Flows after the Use of GT
Cells
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Hybrid Layouts: "ellularlayouts
"haracteristics of the process:
"ells are arranged in relation to each other so that materialmoement is minimied.
Large machines that cannot be split among cells arelocated near to the cells that use them (point of use)
!he layout of machines )ithin each cell resembles a small
assembly line. 0d1ustments can be used to arrange the machines )ithin
the cell.
"omputer programs can be used to locate cells.
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Hybrid Layouts: "ellularlayouts
Example:
$achines are grouped by function into four distinctdepartments.
"omponent parts manufactured in the process layoutsection of the factory are later assembled into a 2nishedproduct on the assembly line.
!he parts follo) di3erent ,o) paths through the shop. !hree representatie routings4 for parts 04 (4 and ".
5or*ers are s*illed )ithin a single department and canoperate more than one machine at a time.
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Hybrid Layouts: "ellularlayouts
6otice:
!he distance that each part must trael beforecompletion
the irregularity of the part routings
0mount of 7paper)or*8 needed to direct the ,o) ofeach indiidual part and to con2rm that the right
operation has been performed
Original
Process
Layouts
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Hybrid Layouts: "ellularlayouts
In its current form, there is no
apparent pattern to the routings.
PRODUCT FLOW ANALYSIS(PFA) reorders part routing
matries to identi!" !ami#ies o!
parts $it% simi#ar proessing
re&uirements'
If we reorder the matrix listing
which parts have four machines
in common, three...Part Routing Matrix
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Hybrid Layouts: "ellularlayouts
Part Routing Matrix Reordered to Highlight Cells
Revised Layout with Three Cells
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Hybrid Layouts: "ellularlayouts
0dantages: %educed material handling
and transit time
%educed setup time %educed )or*inprocess
inentory
(etter use of humanresources
multifunctional )or*ers
Easier to control
Easier to automate
Disadvantages: Inadequate part families
Poorly balanced cells
Expanded training and
scheduling of worers
Increased capital investment
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Types of Layout - ExapleManufacturing Cell
!niated Picture
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Types of Layout - ExapleManufacturing Cell
!n exaple of a hy"rid layout
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Types of Layout - Exaple!utoated Manufacturing Cell
!n exaple of a hy"rid layout
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Types of Layout - Exaple#lexi"le Manufacturing Cell
!n exaple of a hy"rid layout
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Types of Layout - ExapleManufacturing Cell
!n exaple of a hy"rid layout
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Types of Layout - Exaple!utoated Manufacturing Cell
!n exaple of a hy"rid layout
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Types of Layout - Exaple#lexi"le Manufacturing Cell
!n exaple of a hy"rid layout
ypes o ayou
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$or% Cell !sse"ly or Production line-oriented arrangeent ofachines and personnel in what is ordinarily a process-oriented facility& Cells can "e fored on a teporary
"asis&Exaple' (o" shop with rearranged achinery and
personnel to produce )* uni+ue control panels
#ocused $or%
Center
! peranent asse"ly-line-oriented arrangeent ofachines and personnel in what is ordinarily a process-oriented facility
Exaple' anufacturing of pipe "rac%ets at a
shipyard
#ocused #actory ! peranent facility to produce a product or coponent
in a product-oriented facility
Exaple' a plant to produce window echaniss for
autoo"iles
ypes o ayouWork Cell Focused Work Center and
Focused Factory
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9traightline 'lo) attern )hen possible
(ac*trac*ing *ept to a $inimum
redictable roduction !ime
Little ;nprocess materials storage
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!ew Trends in "anufacturing
Layouts
=esigned for +uality and ,exibility
0bility to +uic*ly shift to di3erent productmodels or to di3erent production rates
"ellular layout )ithin larger process layouts 0utomated material handling
>shaped production lines use to betteraccomplish ow control
$ore open )or* areas )ith fe)er )alls4partitions4 or other obstacles
9maller and more compact factory layouts
Less space proided for storage of inentoriesthroughout the layout
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Wrap#up$ttaining Lean Production
'ocus on inentory reduction
(uild systems that help employees
%educe space re+uirements
=eelop close relationships )ith suppliers Educate suppliers Eliminate all but alueadded actiities
=eelop the )or*force
$a*e 1obs more challenging
9et sights on perfection?